Truck Maintenance Checklist

Regular truck maintenance is the backbone of safe and efficient transport operations. A well-maintained truck not only ensures the safety of the driver and other road users but also helps meet strict compliance requirements in the transport industry. From brakes to lights, every component plays a role in keeping the vehicle roadworthy and preventing accidents.

Having a standard maintenance checklist is an effective way for drivers to stay organised and consistent with upkeep. It serves as a reminder to inspect essential systems before, during, and after trips, reducing the risk of unexpected breakdowns or costly repairs.

 

By following a structured checklist, drivers can catch minor issues before they escalate, extend the lifespan of their vehicles, and maintain peak performance. This simple yet powerful habit supports both operational efficiency and peace of mind on the road.

Daily Pre-Trip Inspection

Exterior Check

Walk around the truck to inspect the tyres for proper inflation, correct tread depth, and any cuts, bulges, or uneven wear. Check that all lights, including headlights, tail lights, indicators, and clearance lights, are operational. Make sure mirrors are clean, properly adjusted, and free of cracks. Inspect the windscreen for any chips, cracks, or dirt that could obstruct visibility.

Fluid Levels

Open the hood and check the engine oil using the dipstick, ensuring it is within the recommended range. Inspect coolant levels in the reservoir and top up if necessary, especially before long trips. Check brake fluid and power steering fluid levels, as low levels can indicate leaks or worn components.

Brakes

Test the air pressure system to confirm it reaches the safe operating range before moving. Press the brake pedal to check for firm resistance without excessive softness or sponginess. Verify that brake lights illuminate when the pedal is pressed to ensure following drivers are alerted when you slow down.

Leaks & Damage

Look under the truck and around the engine bay for any signs of leaking fuel, oil, coolant, or hydraulic fluid. Check for visible damage to the chassis, bumpers, or side panels, as well as loose or missing parts that could pose a safety risk during travel.

Weekly Maintenance Tasks

Check Tyre Pressure and Tread Depth

Use a reliable tyre pressure gauge to ensure each tyre is inflated to the manufacturer’s recommended PSI. Inspect tread depth with a tread gauge, ensuring it meets legal requirements and is free from uneven wear, cuts, or embedded objects that could lead to blowouts.

Inspect Battery Terminals and Cables

Open the battery compartment to check for corrosion, loose connections, or frayed cables. Clean the terminals with a wire brush if needed, and ensure the battery is securely mounted to prevent vibration damage during travel.

Test Wipers and Washer Fluid

Activate the wipers to confirm they operate smoothly without streaking or skipping. Check washer fluid levels and top up with an appropriate mix for the season, ensuring you can maintain clear visibility in rain, dust, or dirt conditions.

Verify Load Security and Trailer Connections

Inspect straps, chains, and locks to confirm that cargo is securely fastened and evenly distributed. For trucks pulling trailers, check that the coupling is locked, safety chains are attached, and all electrical connections for lights and brakes are functioning correctly.

Monthly or Scheduled Maintenance

Engine Oil and Filter Change (as per Manufacturer)
Regular oil changes help maintain engine lubrication, prevent overheating, and reduce internal wear. Replace the oil filter to ensure contaminants are removed efficiently, following the interval recommended in the truck’s service manual.

Inspect Belts, Hoses, and Wiring for Wear
Examine serpentine belts and drive belts for cracks, fraying, or glazing. Check hoses for bulges, leaks, or soft spots, as these can lead to coolant or hydraulic failures. Inspect wiring for signs of wear, corrosion, or loose connections that could cause electrical issues.

Check Suspension Components and Steering Alignment
Look for worn bushings, loose bolts, or damaged springs that may affect handling and ride comfort. A steering alignment check helps prevent uneven tyre wear and ensures the truck tracks straight, improving fuel efficiency and driver safety.

Examine Exhaust System for Leaks or Damage
Inspect pipes, clamps, and the muffler for cracks, corrosion, or loose fittings. Exhaust leaks can be dangerous, affecting engine performance and increasing harmful emissions, so prompt repairs are essential.

Seasonal & Long-Haul Maintenance

Prepare Cooling System for Summer Heat
Flush and refill coolant if necessary, and inspect the radiator, hoses, and water pump for leaks or wear. Ensure the fan clutch and thermostat are working properly to prevent overheating during extended summer drives.

Winter Checks: Antifreeze, Heater, Defroster
Test antifreeze strength to ensure it can handle sub-zero temperatures, and check the heater and defroster for proper airflow. Inspect battery health, as cold weather can reduce performance, and make sure wiper blades and washer fluid are winter-ready.

Check Emergency Kit (Flares, First Aid, Tools)
Confirm the kit contains functioning flares or reflective triangles, a stocked first aid kit, basic tools, spare fuses, and jumper cables. For long-haul or remote travel, add blankets, water, and non-perishable food for extra preparedness.

Trailer-Specific Checks

Inspect Coupling/Locking Mechanisms:
Ensure the fifth wheel, kingpin, or other coupling system is securely locked, properly lubricated, and free from cracks or excessive wear. Check safety chains or secondary locking devices for proper attachment.

Test Trailer Brake Systems:

Verify that the trailer’s air or electric brake system engages and releases correctly. Check brake lines for leaks, kinks, or damage, and ensure brake pads or shoes are within safe wear limits.

Check Trailer Lights and Reflectors:

Confirm that all tail lights, brake lights, turn signals, and clearance lights are functional. Clean and inspect reflectors for visibility, especially for night driving or poor weather.

Inspect Trailer Tyres and Suspension:

Measure tyre pressure and tread depth, looking for uneven wear that might indicate alignment or suspension issues. Inspect springs, shocks, and bushings for signs of fatigue or damage.

Record-Keeping & Compliance

Keeping accurate maintenance records is not just good practice; it’s a legal necessity for commercial truck operators. Many transport authorities require proof of regular inspections and repairs to ensure vehicles meet road safety standards. These logs should include the date, type of maintenance performed, parts replaced, and the mechanic or driver responsible for the check.

Proper documentation can protect drivers and companies during roadside inspections or audits, helping to avoid costly fines and penalties. Maintenance records also provide a clear history of the truck’s condition, which is valuable for warranty claims, resale value, and ensuring compliance with both local and national regulations.

Common Mistakes to Avoid

One of the biggest mistakes drivers make is skipping inspections because they feel rushed or are under delivery pressure. Even a short delay in checking your truck can lead to undetected safety hazards that put both the driver and other road users at risk.

Another common error is ignoring small issues such as minor leaks, unusual noises, or slight vibrations. These may seem insignificant at first, but they can quickly escalate into costly repairs or breakdowns if left unchecked.

Finally, using non-genuine or substandard parts for critical components like brakes, suspension, or coupling systems can compromise safety and performance. While cheaper in the short term, poor-quality parts often wear out faster and increase the risk of mechanical failure on the road.

Conclusion

Making a truck maintenance checklist part of your daily and weekly routine is one of the smartest habits any driver can develop. It ensures your vehicle stays in top condition, helps you spot issues early, and keeps you compliant with safety regulations.

Preventive maintenance is more than just a cost-saving measure; it’s an investment in safety, reliability, and peace of mind. By staying proactive, you not only reduce the risk of breakdowns and expensive repairs but also protect lives on the road, including your own.