10 Common Truck Repairs and How to Prevent Them
October 21, 2025 - 8:42:25 am

For a professional truck driver or a fleet manager, there is no sound more costly than silence. A truck that isn't running isn't earning, and unexpected downtime can derail schedules, disappoint customers, and decimate profit margins. While some major failures are unavoidable, a significant percentage of the most common truck repairs are preventable. The secret isn't luck; it's a proactive and disciplined approach to preventative maintenance.

At Wallwork Truck Center, our service bays see it all. We are the experts you call when things go wrong, but our primary mission is to help you prevent those problems from ever happening. This guide is built from decades of hands-on experience. We've compiled a list of the 10 most common truck repairs we encounter and, more importantly, the actionable steps you can take to avoid them, saving you time, money, and headaches.

The Most Common Truck Repairs and Your Prevention Playbook

1. Brake System Failures

The brake system is arguably the most critical safety component on your truck. Failures can range from minor air leaks to complete loss of braking power.

• Why It Happens: Constant use leads to wear on brake pads, shoes, and drums. Air lines can become chafed or cracked, and components like slack adjusters can fall out of calibration.
• How to Prevent It:
• Daily Pre-Trip Inspection: This is non-negotiable. Conduct a daily air brake test (checking for leaks, and testing the low-pressure warning and emergency pop-out valves).
• Visual Checks: Regularly look for cracked or worn brake linings and listen for audible air leaks around fittings and hoses.
• Scheduled Maintenance: During routine service, have a technician inspect and measure brake lining thickness, check slack adjuster travel, and ensure S-cams are properly lubricated and functioning.
• Our Expert Solution: When issues arise, our certified technicians have the expertise to handle everything from a simple brake adjustment to a complete system overhaul, using genuine parts to ensure your truck stops safely, every time.

2. Aftertreatment System Problems (DPF/SCR)

Modern diesel aftertreatment systems are complex and a frequent source of frustrating and expensive truck repairs.

• Why It Happens: Clogged Diesel Particulate Filters (DPF), faulty sensors, and contaminated Diesel Exhaust Fluid (DEF) are common culprits. Interrupted or incomplete regeneration cycles are a primary cause of DPF issues.
• How to Prevent It:
• Allow Full Regens: Whenever possible, allow the truck to complete its regeneration cycle without interruption. This is crucial for burning off soot and keeping the DPF clean.
• Use High-Quality DEF: Never use old, contaminated, or low-quality DEF. Keep your DEF tank and nozzle clean to prevent crystallized fluid from entering the system.
• Address Fault Codes Immediately: An amber check engine light related to the aftertreatment system should be addressed promptly. Ignoring it can turn a minor sensor issue into a major DPF replacement.
• Our Expert Solution: Our technicians are equipped with advanced diagnostic software to accurately pinpoint aftertreatment issues. We can perform forced regens, clean DPF filters, and expertly repair or replace faulty SCR components.

3. Electrical and Wiring Issues

From a single light out to a no-start condition, electrical gremlins can be difficult to trace and can bring a truck to a dead stop.

• Why It Happens: Constant vibration, exposure to moisture, and corrosion are the enemies of a truck's wiring harness. Wires can chafe through their insulation, and connections can become loose or corroded.
• How to Prevent It:
• Keep Connections Clean: Pay special attention to battery terminals. Keep them clean and tight. A coating of dielectric grease can help prevent corrosion.
• Secure the Harness: During visual inspections, look for any wiring harnesses that are hanging loose or rubbing against the frame or other components. Secure them with zip ties to prevent chafing.
• Our Expert Solution: Our team uses advanced diagnostic tools and multimeters to efficiently trace electrical faults, saving you hours of diagnostic labor and getting to the root of the problem quickly.

4. Cooling System Leaks and Overheating

An engine that can't stay cool is an engine on its way to catastrophic failure.

• Why It Happens: Rubber hoses degrade over time, leading to cracks and leaks. Water pumps can fail, and radiators can become clogged with debris, reducing their efficiency.
• How to Prevent It:
• Daily Fluid Checks: Check your coolant level in the overflow reservoir every day.
• Inspect Hoses: Regularly squeeze coolant hoses (when the engine is cool). They should be firm but pliable. If they feel brittle, mushy, or swollen, they are due for replacement.
• Keep it Clean: Keep the exterior of the radiator and charge air cooler clean. A pressure washer (used carefully from a distance) can remove bugs and road grime that block airflow.
• Our Expert Solution: We handle all aspects of cooling system repair, from pressure testing to find elusive leaks to replacing radiators, water pumps, and thermostats.

5. Tire Wear and Blowouts

Tires are your truck's only connection to the road and a major factor in both safety and fuel economy.

• Why It Happens: The leading causes are improper inflation, misalignment, and road hazards.
• How to Prevent It:
• Check Inflation Daily: Use a quality air gauge to check your tire pressures every single day as part of your pre-trip. This is the single most important preventative step.
• Regular Inspections: Look for cuts, bulges, and unusual wear patterns. An unusual pattern can be an early indicator of an alignment or suspension problem.
• Invest in Alignments: A proper truck and trailer alignment is a crucial investment that pays for itself in extended tire life and improved fuel economy.
• Our Expert Solution: Our service centers are equipped with state-of-the-art alignment racks to ensure your truck tracks true, protecting your investment in tires.

6. Suspension Component Wear

Worn shocks, air bags, and bushings lead to a rough ride, poor handling, and can accelerate tire wear.

• Why It Happens: These parts are under constant stress, absorbing the bumps and shocks of the road. Air bags can develop dry rot and leak, while shock absorbers lose their dampening ability over time.
• How to Prevent It: During your walk-around, visually inspect air bags for cracks or chafing. Listen for any unusual clunking or banging sounds when going over bumps, which can indicate worn bushings.
• Our Expert Solution: Our technicians can quickly diagnose suspension issues, from a leaking air bag to worn spring pins and bushings, restoring your truck's ride quality and stability.

7. Fuel System Contamination

Water and debris in your fuel can damage expensive injectors and cause poor engine performance.

• Why It Happens: Condensation in fuel tanks and contaminated fuel from the pump are the primary sources.
• How to Prevent It: Purchase fuel from high-volume, reputable truck stops. Most importantly, make a habit of draining your fuel/water separator daily or as recommended by your manufacturer.
• Our Expert Solution: We can diagnose fuel system issues, replace clogged filters, and provide fuel injector service to restore your engine's power and efficiency.

8. Clutch Wear and Failure

For trucks with manual transmissions, a worn clutch can leave you stranded.

• Why It Happens: Improper shifting techniques (like "riding the clutch") and the simple wear and tear of millions of shifts take their toll.
• How to Prevent It: Proper driver training on shifting techniques is key. Regular clutch adjustments as part of your PM service are also essential to ensure proper engagement and maximize life.
• Our Expert Solution: We offer complete clutch replacement and adjustment services to keep your drivetrain performing flawlessly.

9. Turbocharger Issues

A turbo failure is one of the most serious and costly engine-related truck repairs.

• Why It Happens: The most common causes are oil contamination/starvation or foreign object damage.
• How to Prevent It:
• Strict Oil Maintenance: Never extend your oil change intervals. Use high-quality oil and filters. Clean oil is the lifeblood of a turbo.
• Proper Cool-Down: Allow your engine to idle for a few minutes before shutting it down, especially after a hard pull. This allows the turbo to cool down and prevents oil from "coking" in the bearings.
• Our Expert Solution: Our engine experts can accurately diagnose turbocharger problems and perform professional replacements to get you back on the road with reliable power.

10. HVAC System Failures

While not a "keep you off the road" failure, a non-working HVAC system is a major issue for driver comfort, safety (defrost), and retention.

• Why It Happens: Refrigerant leaks, failed compressors, and clogged cabin air filters are the usual suspects.
• How to Prevent It: Run your air conditioning periodically, even in the winter, to keep the system's seals lubricated. Have your cabin air filters replaced during regular PM service.
• Our Expert Solution: Our service centers are equipped to handle all HVAC repairs, from recharging the system to replacing compressors and condensers.

The Ultimate Prevention: A Partnership with Wallwork Truck Center

Daily pre-trip inspections are your first line of defense, but they are only one piece of the puzzle. The ultimate strategy for preventing major truck repairs is a consistent, professional Preventive Maintenance (PM) program.

Scheduled downtime for maintenance will always be faster, cheaper, and less stressful than unscheduled downtime for a breakdown. At Wallwork Truck Center, our PM programs are designed to be your best defense. Our factory-trained technicians don't just change the oil; they perform comprehensive, multi-point inspections using their expert eyes and advanced diagnostic tools to spot developing issues before they become major failures.

Don't wait for a warning light or a roadside breakdown. Be proactive. Contact your nearest Wallwork Truck Center service department today to schedule a comprehensive inspection or to learn how our tailored PM programs can save you money and keep your fleet on the move.