A Detailed Truck Preventive Maintenance Checklist

Trucks are the backbone of the logistics ecosystem, as they drive the movement of goods across industries. From delivering raw materials to finished products on time, they keep the wheels of business turning.

The efficiency of trucks is regulated by the preventive maintenance process which directly impacts operational efficiency and safety of truck drivers, the support staff working alongside, and every other on the road along which the truck is moving. And the maintenance process is driven by checklists that track everything and keep the process of maintenance organized.

While the maintenance needs of different trucks can vary based on their usage, some components are common across all types. To cover these common and specialized requirements, we have developed a comprehensive generic checklist that covers the shared maintenance tasks for all trucks, along with specialized checklists based on truck type and usage. Before we get to those checklists, let’s have a look at what a truck maintenance checklist means and its important benefits.

What is a Truck Preventive Maintenance Checklist?

A truck preventive maintenance checklist is a management tool for organizing and tracking routine maintenance tasks on a truck. It outlines specific inspections and actions for assessing the condition of all truck components, including engine, brakes, tires, fluid levels, etc. so that the vehicle remains in proper working condition.

What are the Benefits of a Truck Preventive Maintenance Checklist?

A truck preventive maintenance (PM) checklist offers an organized and systematic approach to tracking and performing vehicle inspections and offers the following benefits:

• Consistent Inspections: With a checklist, maintenance becomes a routine, ensuring that no essential task slips through the cracks. This keeps all trucks in top shape and reduces the chance of surprises.
  
• Efficient Tracking: Each truck’s maintenance history is captured, making it easy to track repairs and stay on top of maintenance schedules. The checklist acts as a reliable reference for any follow-up work.
  
• Scheduled Maintenance: Rather than reacting to sudden breakdowns, regular check-ups help pinpoint issues before they cause trouble. This helps avoid unplanned downtime and keeps trucks on the road longer.
• Cost savings: Regular maintenance reduces the risk of unexpected failures, lowering repair costs by preventing major engine or transmission issues. Overall, the maintenance costs come down while keeping service budgets predictable and manageable.
  
• Better Diagnostics: The checklist helps pinpoint recurring problems, making it simpler to address ongoing issues and prevent more serious damage.
  
• Simplified Record Keeping: By having a clear, organized record of each truck’s maintenance, managers can easily plan future repairs and service needs without second-guessing what was last done.

Now, let’s move on to the various truck preventive maintenance checklists that every fleet manager must be using during inspection and maintenance of trucks.

General Truck Preventive Maintenance Checklist

Following is a general checklist, with all the necessary elements, which you must use for preventative maintenance of trucks

1. Engine and Powertrain

• Engine Oil
  • Oil Level: Check engine oil level using the dipstick. Ensure it is within the recommended range.
  • Oil Condition: Check for any unusual color or consistency (should be amber and smooth). If the oil is dark and gritty, it may need to be replaced.
  • Oil Change: Replace engine oil after every specified mileage or as per the manufacturer’s recommendations.
  • Oil Filter: Replace the oil filter with every oil change.
  • Engine Oil Leaks: Check for any visible leaks around the engine.
  • Engine Belts and Pulleys: Inspect belts for wear, cracks, or misalignment. Ensure all pulleys are working smoothly.
  • Timing Belt: Inspect the timing belt (if applicable) for wear or cracking, and replace at the manufacturer-recommended intervals.

• Coolant System
  • Coolant Level: Check coolant reservoir level when the engine is cold.
  • Coolant Condition: Ensure the coolant is clean and not contaminated with debris or rust.
  • Hoses: Inspect all coolant hoses for cracks, leaks, or signs of wear. Replace any damaged hoses.
  • Radiator: Inspect the radiator for leaks, dents, or damage. Check for proper cooling efficiency.
  • Thermostat: Test the thermostat’s functionality.
  • Coolant Flush: Replace coolant specified mileage or per manufacturer recommendations.
  • Water Pump: Check the water pump for leaks or unusual noise, ensuring it operates effectively.

• Transmission and Differential Fluid
  • Transmission Fluid: Check fluid level, color, and consistency. If the fluid appears burnt or dark, replace it.
  • Differential Fluid: Check differential fluid level and condition.
  • Transmission Lines: Inspect transmission lines for leaks or damage.
  • Clutch (if manual): Check clutch for proper function, wear, and smooth engagement.

• Fuel System
  • Fuel Filters: Replace fuel filters every specified mileage or as specified by the manufacturer.
  • Fuel Lines: Inspect for signs of leaks, cracks, or corrosion. Replace damaged fuel lines.
  • Fuel Tank: Inspect for dents, rust, or cracks. Ensure the fuel tank is securely attached.
  • Fuel Injectors: Inspect fuel injectors for signs of wear or clogging, and clean or replace if necessary.
    

• Air Intake System
  • Air Filter: Inspect air filter for dirt, damage, or clogging. Replace air filter every specified mileage.
  • Air Ducts: Check air intake ducts for cracks or blockages.
  • Turbocharger (if applicable): Inspect for leaks or wear. Clean air intakes regularly to avoid clogging.
    

• Exhaust System
  • Exhaust Pipe: Inspect for any visible rust, cracks, or leaks.
  • Muffler: Check for signs of damage, rust, or holes.
  • Emissions Control System: Inspect the catalytic converter, DPF (Diesel Particulate Filter), and EGR (Exhaust Gas Recirculation) valve for proper function.
  • Exhaust Manifold: Check for exhaust leaks or cracks in the manifold.
    

2. Braking System

• Brake Pads and Shoes
  • Thickness: Check brake pads or shoes for wear. Replace them when thickness reaches 3–5mm.
  • Wear Indicators: Inspect wear indicators to ensure they’re functioning correctly.
  • Squealing or Grinding: Listen for any unusual noises when braking. These might indicate worn brake pads.

• Brake Fluid
  • Fluid Level: Check brake fluid level and top up if necessary.
  • Fluid Condition: Check the condition of the fluid. Replace if it is dirty or contaminated.
  • Brake Fluid Change: Replace brake fluid at regular intervals or as recommended by the manufacturer.
  • Brake Fluid Leaks: Check for signs of brake fluid leaks around master cylinder, brake lines, and calipers.

• Brake Lines and Hoses
  • Leaks: Inspect all brake lines and hoses for visible leaks, cracks, or signs of wear.
  • Corrosion: Look for signs of corrosion on the brake lines and fittings. Replace as necessary.
  • Brake Pressure Test: Perform a brake pressure test to check the integrity of the system.

• Brake Rotors and Drums
  • Condition: Inspect brake rotors for cracks, scoring, or uneven wear. Check brake drums for scoring or cracks.
  • Thickness: Measure rotor thickness and replace if it’s below the manufacturer’s minimum specifications.
  • Brake Pad Bedding: Check that the brake pads are bedding properly against the rotors.

• Air Brake System (for air-brake trucks)
  • Compressor: Check the air compressor for proper operation and leaks.
  • Tanks: Inspect air brake tanks for moisture and corrosion. Drain moisture regularly.
  • Air Pressure: Check for the proper air pressure and listen for air leaks in the system.
  • Air Dryer: Inspect the air dryer for contaminants and ensure it is functioning correctly.

• Parking Brake
  • Functionality: Test parking brake to ensure it engages and disengages properly.
  • Adjustment: Ensure proper tension and adjust as needed.

3. Tires and Wheels

Tire Pressure

• Check Pressure: Measure tire pressure with a gauge, ideally when tires are cold. Adjust to manufacturer’s specifications.
• Pressure Monitoring System: If equipped, verify that the tire pressure monitoring system is functioning correctly.

• Tire Condition
  • Tread Depth: Measure tread depth regularly and replace tires when the tread depth falls below the manufacturer’s recommended level.
  • Uneven Wear: Inspect for signs of uneven wear, which could indicate alignment or suspension issues.
  • Cracks and Bulges: Check the sidewalls and tread for cracks, cuts, or bulges that might indicate a tire that’s unsafe to use.
  • Tire Sidewall: Inspect sidewalls for punctures, gouges, or excessive wear.

• Tire Rotation
  • Rotation Schedule: Rotate tires every 6,000–8,000 miles to ensure even wear.
  • Alignment: Inspect for misalignment and correct if necessary to avoid abnormal tire wear.

• Wheel Inspection
  • Wheels: Inspect wheels for cracks, rust, or damage. Ensure that all lug nuts are tightened to the manufacturer’s torque specifications.
  • Wheel Rim: Inspect wheel rims for dents or cracks.

4. Suspension and Steering

• Shock Absorbers and Struts
  • Condition: Inspect for leaks, dents, or damage. Ensure shock absorbers and struts are in good condition.
  • Performance: Test the shock absorbers for proper damping performance. Replace if worn out.

• Ball Joints and Tie Rods
  • Condition: Check for signs of wear, such as excessive play, cracks, or fraying.
  • Lubrication: Ensure that the ball joints and tie rods are properly lubricated.

• Suspension Bushings
  • Inspection: Inspect suspension bushings for wear, cracks, or damage.

• Steering Rack
  • Leaks: Inspect the steering rack and hydraulic pump for leaks.
  • Functionality: Check for any unusual play or resistance in the steering.

• Power Steering Fluid
  • Fluid Level: Check fluid level and top up as necessary.
  • Fluid Condition: Ensure the fluid is clean and not contaminated. Replace if needed.

• Steering Column and Linkages
  • Check: Inspect the steering column for smooth operation. Ensure that linkages are secure and show no signs of wear.
    

5. Electrical System

• Battery
  • Charge and Voltage: Test battery voltage with a multimeter (should read between specified range for a fully charged battery).
  • Terminals: Inspect battery terminals for corrosion or loose connections. Clean terminals if necessary.
  • Battery Age: Check the battery’s age and replace it if it exceeds the specified lifespan.
  • Battery Cables: Inspect for corrosion or damage to the cables and connectors.
    

• Alternator
  • Voltage Output: Measure the alternator’s output using a voltmeter. It should read between specified ranges when the engine is running.
  • Belts and Wiring: Inspect the alternator’s drive belt for wear, and check the wiring for any signs of fraying.
    

• Lights and Indicators
  • Headlights/Taillights: Test headlights, brake lights, turn signals, and reverse lights. Replace bulbs as needed.
  • Interior Lights: Ensure all interior lights (dashboard, cabin, and cargo area lights) are functioning.
  • Emergency Flashers: Verify that hazard lights work correctly.
    

• Fuses and Relays
  • Inspect Fuses: Check the fuse box for any blown fuses and replace them.
  • Relays: Test all relevant relays to ensure they function correctly.
    

• Wiring and Electrical Connections
  • Condition: Inspect all visible wiring for fraying, wear, or shorts. Repair any damaged wiring.
    

6. Fuel System

• Fuel Filter
  • Replace Fuel Filter: Replace the fuel filter every specified mileage or as per the manufacturer’s recommendation.
    

• Fuel Lines and Hoses
  • Inspection: Check for fuel leaks or any wear and tear on the fuel lines and hoses.
    

• Fuel Tank
  • Inspection: Ensure the fuel tank is free of rust and secure.
  • Check Fuel Cap: Inspect the fuel cap to ensure it fits securely and does not leak.
    

• Fuel Tank Straps
  • Condition: Check the fuel tank straps for rust, damage, or wear. Tighten or replace as necessary.

7. Safety Equipment

• Fire Extinguisher
  • Inspection: Ensure the fire extinguisher is fully charged and easy to access. Inspect the safety pin and nozzle for blockages.
  • Expiration Date: Check the expiration date and replace the fire extinguisher if expired.
    

• First Aid Kit
  • Complete Inventory: Ensure the first aid kit contains all necessary items (bandages, antiseptic wipes, gauze, etc.).
  • Expiration Dates: Check the expiration dates of any medications or sterile supplies.
    

• Emergency Triangle / Flares
  • Visibility: Ensure that the emergency triangles or flares are visible and in working condition.
    

• Seatbelts
  • Functionality: Inspect all seat belts for proper operation, fraying, or damage.
  • Adjustment: Ensure that seatbelts are adjustable and retract properly.
    

8. General Exterior and Interior Inspection

• Body and Frame
  • Inspection: Look for any visible rust, dents, or cracks on the truck’s body and frame.
    

• Windshield and Wipers
  • Windshield Condition: Inspect for cracks or chips. Replace if necessary.
  • Wiper Blades: Inspect wiper blades for wear or damage. Replace blades at regular intervals.
  • Washer Fluid: Check the windshield washer fluid reservoir and top up if necessary.
  • Wiper Motor: Inspect wiper motor for proper function.

Preventive Maintenance Checklists Based on Truck Types

The above checklist covers all the common evaluation criteria. However, maintenance of specialized trucks requires assessment against truck-specific elements. Based on different truck types, following are the useful checklists.

Light Duty Trucks

Useful for: Pickup Trucks, Panel Trucks, Flatbed Trucks

• Bed/Platform Inspection (for Flatbed Trucks)
  • Inspect the truck bed for cracks, rust, and wear, especially around the mounting points.
  • Check tie-downs and ensure they are secure and functional for load-bearing.
  • Inspect wood flooring (if applicable) for rotting or damage.
    

• Cargo Area (for Pickup and Panel Trucks)
  • Check for any damage or wear in the cargo area. Ensure panels are free of dents or cracks.
  • Inspect the cargo door for smooth opening/closing and secure latching.
    

• Suspension (for Pickup Trucks)
  • Inspect the leaf springs and suspension for wear or damage, especially if the truck is used for heavy hauling.
    

• Bed Liner (for Pickup Trucks)
  • Check the condition of bed liners for wear or damage, and replace if necessary.
    

Medium Duty Trucks

Useful for: Box Trucks, Delivery Trucks, Stake Trucks, Tow Trucks

• Box/Body Inspection (for Box and Delivery Trucks)
  • Inspect the cargo area for signs of structural damage or wear.
  • Check the integrity of the floor and side walls, ensuring no cracks or weaknesses in the body.
  • Ensure the door seals are intact to maintain the truck’s weatherproofing.
    

• Lift Gate (for Box Trucks)
  • Inspect the lift gate for proper operation, smooth function, and secure attachment.
  • Lubricate lift gate components to prevent rust and ensure smooth operation.
    

• Tow Equipment (for Tow Trucks)
  • Check the winch and tow cables for wear, fraying, or damage.
  • Inspect the hydraulic system for leaks or pressure loss.
  • Test the recovery system to ensure it’s functional and safe.
    

• Stake Bed Inspection (for Stake Trucks)
  • Inspect the stake bed structure for damage or wear, ensuring that stakes and posts are secure.
  • Check that all fastening systems for the stake body are in working order.

Heavy Duty Trucks

Useful for: Semi-Trucks, Dump Trucks, Cement Mixer Trucks, Refrigerated Trucks, Tanker Trucks

• Tractor and Trailer Coupling (for Semi-Trucks)
  • Inspect the fifth wheel coupling for proper lubrication, cracks, and smooth engagement with the trailer.
  • Check the air and electrical connections between the truck and trailer for wear or damage.
    

• Dump Mechanism (for Dump Trucks)
  • Inspect the hydraulic lift system for proper function and fluid levels.
  • Ensure the dump body is free from cracks and damage.
  • Test the dump bed for smooth operation and secure locking when raised.
    

• Mixer Drum and Hydraulic System (for Cement Mixer Trucks)
  • Inspect the mixing drum for wear or cracks, and ensure it rotates smoothly.
  • Check hydraulic systems that control the drum for leaks, fluid levels, and proper operation.
    

• Refrigeration Unit (for Refrigerated Trucks)
  • Check the refrigeration unit for proper temperature control and operation.
  • Inspect the condenser and evaporator coils for cleanliness, debris, or damage.
  • Monitor the refrigerant levels and replace as needed.
    

• Tanker Inspection (for Tanker Trucks)
  • Inspect the tank for signs of leaks, corrosion, or dents.
  • Check the safety valve and pressure relief system for proper function.
  • Test the pumping mechanism for functionality.
  • Inspect the interior of the tank for residue or corrosion, and clean as required.
    

• Air Brake System (for Heavy Trucks)
  • Inspect air compressor and air tanks for leaks or moisture buildup. Drain moisture regularly.
  • Test air brakes for responsiveness and adjust if necessary.
    

Special-purpose Trucks

Useful for: Concrete Pump Trucks, Crane Trucks, Car Carrier Trucks, Garbage Trucks

• Boom and Hydraulic Systems (for Concrete Pump Trucks and Crane Trucks)
  • Inspect the boom for cracks or signs of metal fatigue.
  • Check all hydraulic hoses for leaks, wear, and secure fittings.
  • Test hydraulic pumps and motors for smooth operation.
  • Lubricate all moving parts and check hydraulic fluid levels regularly.
    

• Carrying System (for Car Carrier Trucks)
  • Inspect the ramps, lifting systems, and hydraulic motors for smooth operation.
  • Check for structural integrity of the ramps and securing system.
  • Test the securing mechanisms for proper locking.
    

• Compaction Mechanism (for Garbage Trucks)
  • Inspect the compactor for smooth operation, checking hydraulic systems for leaks or issues.
  • Ensure the compacting blade and body are free of blockages or damage.
  • Test the unloading system to ensure it functions correctly.
    

Emergency and Utility Trucks

Useful for: Fire Trucks, Ambulance Trucks, Utility Service Trucks, Tow Trucks

• Firefighting Equipment (for Fire Trucks)
  • Inspect hoses for wear, cracks, or damage.
  • Test water pump for proper function and pressure levels.
  • Check all nozzles and spray mechanisms for clogging or damage.
  • Inspect the ladder and its hydraulic mechanisms for smooth operation.
    

• Medical Equipment (for Ambulance Trucks)
  • Test all life-support equipment to ensure it’s functional (e.g., defibrillators, oxygen tanks).
  • Inspect the stretcher and lifting system for smooth operation.
  • Check for clean and fully stocked medical supplies, and ensure they are within expiration dates.
    

• Utility Service Equipment (for Utility Service Trucks)
  • Inspect the crane or lift equipment for wear, cracks, or fluid leaks.
  • Test the generator and any electrical equipment for proper operation.
  • Check any specialized tools for functionality and proper storage.
    

• Tow Gear (for Tow Trucks)
  • Inspect the tow boom and winch for proper operation.
  • Check the towing lights and safety mechanisms for proper function.
    

Military Trucks

Useful for: Armored Personnel Carriers, Tactical Trucks, Military Cargo Trucks

• Armor and Chassis (for Armored Personnel Carriers)
  • Inspect the armor for damage, cracks, or wear that could compromise safety.
  • Check the suspension for excessive wear due to the added weight of armor.
    

• Tactical Equipment (for Tactical Trucks)
  • Ensure that any mounted weapons or equipment are secure and functional.
  • Test all communication and navigation systems for operation.
  • Inspect and maintain any ballistic protection systems.
    

• Cargo Area (for Military Cargo Trucks)
  • Inspect the bed or cargo area for structural integrity and proper mounting of military gear.
  • Ensure the truck has all necessary tools and spare parts for mission-specific requirements.

Heavy Equipment Transport Trucks

Useful for: Lowboy Trucks, Heavy Haul Trucks

• Lowboy Trailer (for Lowboy Trucks)
  • Inspect the ramps for wear, structural damage, or cracks.
  • Check the hydraulic system for leaks or fluid loss.
  • Inspect the trailer bed for even wear or damage caused by heavy loads.
    

• Heavy Haul Truck Inspection (for Heavy Haul Trucks)
  • Inspect the specialized suspension system for proper load handling.
  • Ensure that all load-bearing components are rated for the weight being transported.
  • Verify the integrity of the trailer and its attachment points.

What are the Tips to Follow for Truck Maintenance?

• Inspect Tires Regularly
  Keeping tires properly inflated and free from damage reduces the risk of blowouts and improves fuel efficiency.

• Change Oil and Filters on Time
  Timely oil and filter changes keep the engine running smoothly and prevent costly repairs.

• Monitor Brake Health
  Regular brake inspections help maintain safe stopping power and avoid sudden system failures.

• Keep the Cooling System in Check
  A healthy cooling system prevents the engine from overheating, especially during long hauls or heavy loads.

• Check and Replace Belts and Hoses
  Worn belts and cracked hoses can cause breakdowns, so inspecting and replacing them on time keeps the truck dependable.

• Maintain Battery Health
  Cleaning terminals and checking battery voltage regularly helps avoid starting issues and electrical failures.

• Inspect Suspension Components
  Keeping an eye on shocks, struts, and other suspension parts improves ride comfort and prevents uneven tire wear.

• Test Lights and Electrical Systems
  Regularly checking all lights and wiring ensures safety on the road and prevents violations during inspections.

• Lubricate Moving Parts
  Proper lubrication of joints, hinges, and bearings reduces wear and extends the life of mechanical parts.

• Keep the Truck Clean
  Washing the truck and undercarriage regularly removes grime, salt, and debris that can cause corrosion and mechanical problems.

To Wrap Up

Ignoring vehicle maintenance can lead to increased roadside assistance calls, costly fines, operational disruptions, and, in the worst cases, accidents with fatal consequences. A comprehensive preventive maintenance checklist for trucks is crucial to avoid these risks, keep trucks in top condition, and ensure safe, uninterrupted service.

May it be commercial trucks or semi trucks, the checklists we offered in the preceding part will serve the purpose and you will be able to carry out the maintenance process with utmost efficiency. Framing a good maintenance program requires that you follow these checklists when going through your PM schedules.

At the same time, it is essential for you to understand what impact technology can make here. As fleet managers, you must implement FieldCircle fleet maintenance software which is integrated with all the necessary checklists. This will take the guesswork out of fleet management and you will be able to easily stay on top of maintenance tasks, making it smooth sailing for your fleet.