Ultimate Truck Maintenance Checklist 2025
Maintaining your commercial truck fleet in optimal condition is essential for safety, compliance, and profitability in today's competitive transportation industry. At Heavy Vehicle Inspection, we've developed this comprehensive maintenance checklist incorporating the latest industry standards and best practices to ensure your fleet remains in peak operational condition. Regular preventive maintenance not only extends vehicle lifespan but also minimizes unexpected breakdowns, enhances fuel efficiency, and ensures compliance with DOT regulations and FMCSA requirements.
Why Professional Truck Inspections Matter
Professional commercial vehicle maintenance is the foundation of any successful fleet operation. Industry studies show that systematic preventive maintenance can reduce repair costs by up to 30% and extend heavy-duty truck lifespan by 20-25%. Beyond significant cost savings, proper maintenance directly impacts safety compliance, CSA scores, and your transportation company's reputation in the logistics industry.
Pro Tip: Implementing a digital maintenance tracking system alongside this printable checklist can improve DOT compliance by up to 45% and reduce fleet administrative overhead. Visit digital solutions to learn more.
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Commercial Fleet Maintenance Essentials
A properly maintained commercial truck can operate 15-20% more efficiently, saving thousands in diesel fuel costs annually. Our inspection checklist is designed by ASE-certified technicians with over 25 years of experience in heavy-duty truck maintenance and DOT compliance. For personalized fleet maintenance solutions, visit
Commercial Truck Inspection & Maintenance Checklist
Vehicle ID/VIN Number: ______________________
Engine Hours/Mileage: ______________________
Make/Model/Year: ______________________
CDL Operator Name: ______________________
Inspection Date: ______________________
DOT Number: ______________________
1. Pre-Trip DOT Inspection Checklist
Exterior Safety Checks:
▢ Inspect headlights, taillights, turn signals and reflectors
▢ Check commercial truck tires for wear, damage, and proper PSI
▢ Inspect side mirrors for proper adjustment and damage
▢ Check windshield, wipers and washer fluid levels
▢ Inspect diesel fuel tanks and caps for security
▢ Verify all DOT-required markings and placards
Trailer & Cargo Area:
▢ Inspect cargo securement devices and load restraints
▢ Check for proper weight distribution and gross vehicle weight
▢ Verify fifth wheel connection, kingpin and landing gear
▢ Inspect trailer doors, seals and locking mechanisms
▢ Check reefer unit operation (if applicable)
▢ Verify trailer brake connections and gladhand couplers
2. Engine Compartment & Powertrain Inspection
Diesel Engine Fluid Levels:
▢ Engine oil level and oil change interval check
▢ Coolant level, concentration and freeze protection
▢ Power steering fluid level and condition
▢ DEF (Diesel Exhaust Fluid) level and quality
▢ Hydraulic brake fluid level (if applicable)
▢ Transmission fluid level and condition
Engine Components:
▢ Check for fluid leaks and oil seepage
▢ Inspect serpentine belts for wear, cracks and tension
▢ Check cooling system hoses for deterioration
▢ Inspect air filter and air intake system
▢ Check battery connections, charge and load test
▢ Inspect starter, alternator and charging system
3. Commercial Vehicle Brake System Inspection
▢ Check air brake system pressure and governor cut-in/out
▢ Test parking brake and spring brake functionality
▢ Inspect air brake lines for leaks, kinks or damage
▢ Check brake pad/shoe thickness and wear patterns
▢ Verify brake chamber stroke measurements
▢ Inspect brake hoses and gladhand connections
▢ Inspect brake drums/rotors for cracks or scoring
▢ Test service brake operation and stopping distance
▢ Check brake chamber mounting and security
▢ Verify ABS system operation and warning lights
▢ Inspect slack adjusters and S-cam components
▢ Check brake balance and adjustment
Pro Tip for DOT Compliance:
During air brake inspection, listen for air leaks when the brake pedal is applied. A continuous hissing sound indicates a leak that requires immediate attention to avoid DOT violations. Modern commercial air brake systems should not lose more than 3 psi per minute with brakes applied.
4. Drivetrain and Chassis Inspection
▢ Inspect driveshaft, U-joints and center bearing
▢ Check transmission mounts and gear selection
▢ Inspect differential fluid level and condition
▢ Check wheel bearings for play and lubrication
▢ Inspect clutch free play and engagement (if manual)
▢ Check PTO operation (if equipped)
▢ Inspect frame rails and crossmembers for cracks
▢ Check suspension components, air bags and leveling
▢ Inspect steering components, linkage and power assist
▢ Check wheel hub oil level and condition
▢ Inspect axle alignment and wheel tracking
▢ Check mounting hardware and fasteners
5. Heavy-Duty Truck Cabin Inspection
▢ Test air horn and city horn functionality
▢ Check DOT-required seatbelts for proper operation
▢ Verify all dash gauges and warning indicators
▢ Test HVAC system for proper heating and cooling
▢ Check all interior lights and controls
▢ Inspect windshield for cracks and visibility
▢ Verify fire extinguisher mounting and charge status
▢ Check emergency equipment and first aid kit
▢ Test low air warning devices and buzzers
▢ Inspect interior mirrors for proper adjustment
▢ Verify ELD system functionality and compliance
▢ Check driver's seat mounting and adjustment
6. Diesel Emission Control Systems Inspection
▢ Inspect DEF level, quality and system operation
▢ Check SCR (Selective Catalytic Reduction) system
▢ Inspect DPF (Diesel Particulate Filter) status
▢ Verify DPF regeneration cycle operation
▢ Check diesel oxidation catalyst condition
▢ Verify no active emission fault codes with scanner
▢ Check exhaust system for leaks and secure mounting
▢ Inspect EGR (Exhaust Gas Recirculation) system
▢ Check exhaust aftertreatment components
▢ Verify emission control warning lights
7. Scheduled Preventive Maintenance Checks
Monthly Fleet Maintenance:
▢ Check air dryer functionality and purge valve
▢ Inspect air compressor operation and governor
▢ Lubricate chassis components and grease points
▢ Check battery electrolyte levels (if applicable)
▢ Inspect electrical connections and harnesses
▢ Check fifth wheel operation, lubrication and wear
▢ Verify onboard diagnostics and fault codes
▢ Inspect cooling system and radiator condition
Quarterly Commercial Truck Maintenance:
▢ Perform oil analysis for preventive maintenance
▢ Check wheel alignment and tire wear patterns
▢ Inspect fuel system components and filters
▢ Verify fuel economy and performance metrics
▢ Test cooling system protection and SCA levels
▢ Inspect turbocharger operation and boost pressure
▢ Check clutch adjustment and free play (if applicable)
▢ Inspect HVAC system refrigerant and function
Annual DOT Inspection & Maintenance:
▢ Complete Federal DOT annual inspection
▢ Perform complete brake system overhaul
▢ Replace air dryer cartridge and purge valve
▢ Conduct complete chassis lubrication service
▢ Inspect/replace transmission filters and fluid
▢ Service wheel bearings and check endplay
▢ Clean/inspect radiator, charge air cooler and A/C condenser
▢ Perform complete engine diagnostic analysis
8. Commercial Vehicle Defects and Issues Documentation
Document any defects or DVIR issues discovered during inspection:
1. _____________________________________________________________
2. _____________________________________________________________
3. _____________________________________________________________
4. _____________________________________________________________
5. _____________________________________________________________
For immediate assistance with critical defects, contact Heavy Vehicle Inspection at 1-800-555-1234 or visit
9. Fleet Maintenance Verification
Maintenance Performed By: _______________________
Technician Certification #: _______________________
Date: _______________________
Technician Signature: _______________________
Next PM Service Due: _______________________
Next DOT Inspection: _______________________
Commercial Fleet Maintenance SOPs
Implement these Standard Operating Procedures to maximize the effectiveness of your fleet maintenance program:
- Daily DVIR Inspections: Complete pre-trip and post-trip Driver Vehicle Inspection Reports every operating day as required by FMCSA
- Maintenance Documentation: Maintain all truck maintenance records for a minimum of 3 years to ensure DOT compliance
- OEM Scheduled Maintenance: Follow manufacturer-recommended service intervals for your specific make and model
- Defect Reporting Protocol: Report all safety defects immediately to maintenance personnel and document them properly
- Regulatory Compliance: Ensure all maintenance meets or exceeds FMCSA and DOT requirements for commercial vehicles
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Conclusion: The Value of Professional Truck Maintenance
Implementing this comprehensive heavy vehicle maintenance checklist is essential for fleet operators who prioritize safety, DOT compliance, and cost efficiency. By following our 2025 updated inspection protocol, you can significantly reduce roadside breakdowns, extend commercial vehicle lifespan, improve diesel fuel economy, and ensure full regulatory compliance with FMCSA requirements. Remember that consistent application of this checklist, combined with proper documentation and prompt follow-through on identified issues, forms the foundation of an effective fleet maintenance program.
For best results, train all personnel on proper commercial vehicle inspection techniques and establish clear communication channels between CDL drivers, maintenance technicians, and fleet management. This proactive approach to truck maintenance will pay dividends through improved reliability, safety, and operational efficiency. For personalized assistance with your fleet maintenance program, contact the ASE-certified experts at Heavy Vehicle Inspection today.
For commercial vehicles, DOT regulations require daily pre-trip and post-trip inspections (DVIRs), along with more comprehensive preventive maintenance inspections according to the manufacturer's recommendations. Generally, this includes monthly, quarterly, and annual inspection schedules. Daily inspections typically take 15-30 minutes, while comprehensive DOT inspections may require several hours. Annual DOT inspections are legally required and must be documented with a proper inspection report. Learn more about DOT inspection schedules.
The most common commercial truck maintenance issues that lead to CSA violations include brake system problems (27% of all violations), tire wear/damage (19%), lighting and electrical system failures (14%), engine performance issues (12%), and fluid leaks (9%). Regular preventive maintenance using our comprehensive checklist can help identify these issues before they lead to breakdowns or violations.
To maximize diesel fuel efficiency, focus on proper tire inflation (can improve fuel economy by up to 3%), regular air filter replacement (up to 10% improvement), quality engine oil and filters, aerodynamic component maintenance, and engine performance tuning. Our checklist includes all these critical areas to help you achieve optimal fuel economy.
The FMCSA requires carriers to maintain systematic inspection, repair, and maintenance records for all vehicles under their control. These records must include: identification of the vehicle (VIN, make, year), maintenance history, inspection reports, repair verification, and lubrication records. All records must be retained for at least 12 months while the vehicle is in your control and 6 months after.
Implementing an effective preventive maintenance program requires: establishing a maintenance schedule based on time, mileage, or engine hours; training drivers on proper inspection techniques; using a reliable tracking system; setting up automated maintenance alerts; designating responsible personnel; creating standardized procedures; tracking metrics; and continuous improvement.
