Top 10 Fleet Maintenance Lies Transporters Still Believe

From 'if it’s not leaking, it’s fine' to 'OEM settings never need adjustment' – a reality check on the most common fleet maintenance myths that silently destroy trucks and trailers.

📅 Published on 2025-12-17 | ✍️ Semi Trailer News Technical Desk

Image: Fleet manager reviewing a maintenance checklist for trucks and trailers

Every fleet owner says they care about maintenance – but workshop data tells a different story. Breakdowns on the road, unexpected EBS errors, cracked chassis, overheating wheel-ends… Most of these are not “bad luck”. They come from a set of dangerous maintenance myths that never die in the transport industry.

Below are the Top 10 fleet maintenance lies that still cost transporters money, uptime and reputation – and what the engineering reality looks like behind each one.

1️⃣ “If It’s Not Leaking, It’s Fine”

Many operators only react when they see visible oil, air or coolant leaks. The problem is that most critical failures start long before anything drips onto the ground:

• Wheel bearings running too hot but not yet leaking grease
• Air system losing pressure slowly due to micro leaks
• Hydraulic ramps with internal bypass but no external oil trace

By the time a leak becomes visible, the component is usually already damaged. Reality: Temperature trends, pressure loss tests and regular torque checks catch problems before they leak.

2️⃣ “Brand-New Trailers Don’t Need Inspection”

It sounds logical: a brand-new trailer has just left the factory, so why should a fleet check anything? Yet the first 10 000 km are often where:

• Loose wheel nuts and suspension bolts appear
• Incorrect tyre pressures reveal themselves under load
• Small production tolerances result in uneven brake balance

Reality: New trailers need a first service after initial loading and real-road operation – not as a favour to the manufacturer, but to protect your investment.

3️⃣ “Drivers Will Notice Any Serious Problem”

Drivers are your first line of defence – but they cannot:

• See EBS modulators overheating behind the axles
• Hear every small air leak under city noise conditions
• Smell every burning brake when driving in convoy

Reality: Pre-trip checks and daily walk-arounds are essential, but they cannot replace scheduled workshop inspections with proper tools.

4️⃣ “Winter Preparation Is Only for Cold Countries”

Many fleets in “mild” climates believe they don’t need winter preparation. Then the first cold week arrives and they discover:

• Frozen brake valves due to water in air tanks
• Batteries that collapse under low temperatures
• Condensation in electrical junction boxes causing errors

Reality: Draining air tanks, testing batteries, checking lights and using proper greases is cheap – roadside breakdowns are not.

5️⃣ “OEM Settings Never Need Adjustment”

It is a popular belief that EBS, ABS and suspension settings are sacred and must never be touched. In reality, OEMs expect:

• Correct trailer loading scenarios to be programmed (load sensing)
• Tyre rolling radius to match the configuration in the ECU
• Correct axle lift and steering logic per fleet usage

Reality: OEM settings are a starting point. If fleets change tyre size, add lift axles or modify trailer use, the parameters must follow.

6️⃣ “Greasing Everything More Often Is Always Better”

Under-greasing causes wear – but over-greasing causes:

• Blown seals on bushes and kingpins
• Contaminated brake linings and drums
• Dirt and sand sticking to exposed grease films

Reality: Grease according to specified intervals and use the right grease type for each component. “More” is not always “better”.

7️⃣ “We’ll Fix It When It Fails”

Run-to-failure sounds cost-effective on paper. In practice, it means:

• Emergency roadside repairs at premium labour rates
• Missed deliveries and angry customers
• Collateral damage – a cheap hose destroying an expensive component

Reality: A basic preventive maintenance plan costs less over the lifecycle than constantly reacting to failures.

8️⃣ “Electrics Are Either Working or Not Working”

Many fleets think of electrical systems in black-and-white terms. Either the lights are on, or they are off. In reality, most failures start as:

• Intermittent ground faults
• Corroded junction boxes and connectors
• Damaged wiring near the kingpin or rear crossmember

Reality: Voltage drop tests, visual inspections and proper sealing of connectors stop electrical nightmares before they become chronic.

9️⃣ “Aftermarket Parts Are All the Same”

There is a huge difference between:

• Genuine parts from OEMs
• Approved aftermarket parts
• Unknown low-cost copies with no testing or traceability

Using the cheapest possible brake valves, airbags or slack adjusters often looks smart for a few months – until failures start to appear across the fleet.

Reality: The part that is 30% cheaper can easily create a failure that is 300% more expensive than the original saving.

🔟 “Data & Telematics Are Only for Big Fleets”

Smaller fleets often say: “We have only 10 trailers, we don’t need telematics.” But:

• One breakdown can wipe out the profit of a whole month
• Basic tracking and EBS data reveal recurring technical issues
• Simple mileage-based maintenance planning is possible even for micro fleets

Reality: You don’t need a full control room – even simple odometer and diagnostic data help prevent expensive surprises.

🧮 Fleet Downtime & Cost Estimator

🏁 Conclusion

Fleet maintenance is not just about changing oil and tyres. It is about killing dangerous myths that keep trailers on the road “until something breaks”. The most profitable fleets are not the ones that avoid maintenance – they are the ones that:

• Plan inspections based on real usage
• Train drivers and technicians together
• Use data from EBS, telematics and workshop systems
• Understand that every unplanned stop is a hidden invoice

Once you stop believing these 10 lies, your trailers will last longer, your drivers will be safer and your customers will see the difference.

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