How fleets balance aging trucks with smarter maintenance
Key takeaways:
- To help increase vehicle lifecycles, optimize your preventative maintenance schedule based on a truck's age, mileage, climate exposure, and usage patterns
- Be sure to leverage predictive maintenance and telematics to analyze fault codes, telematics data, and past performance to look for when a breakdown is coming
- Be sure to track maintenance metrics like components lifespan, repairs, and breakdown frequency, while maintaining technician and driver training
For more on preventive and predicitve maintenance:
ACT Research has recently provided another update on the current fortunes of the trucking industry, and not for the better. This month's preliminary report found that Class 8 orders are down 44% YOY, while medium-duty Classes 5-7 are down 22% YOY. In turn, OEMs are scaling back production.
This means that shops are likely to see more work in their bays as fleets increasingly leverage the used truck market for new purchases and drivers keep their trucks longer. But this also impacts the kind of work technicians will need to do, as instead of servicing newer vehicles, they'll be working to keep aging trucks running longer without any sacrifices to safety and efficiency. To do that, maintenance departments need to do more than regular preventative maintenance (PM); they must incorporate proactive, data-driven maintenance programs.
Optimize preventive maintenance schedules to extend truck life cycles and reduce downtime
A solid PM schedule remains the backbone of fleet reliability. Regular inspections and service intervals prevent minor issues from becoming major repairs. However, as trucks age, PM schedules can’t be a one-size-fits-all.
Fleet managers should assess maintenance intervals based on each truck’s age, mileage, climate exposure, and usage patterns. For instance, vehicles operating in colder regions face additional wear from ice, salt, and temperature extremes.
The key is consistency and flexibility. Even when a PM must be rescheduled, fleets need systems in place to track compliance and reassign service appointments promptly. Skipping maintenance isn’t an option when extending asset life cycles is the goal.
Leverage predictive maintenance and telematics to prevent costly breakdowns
Preventive maintenance is about planning; predictive maintenance is about foresight. By using real-time vehicle data and diagnostics, maintenance teams can spot potential failures before they lead to downtime. Predictive tools analyze fault codes, telematics data, and historical performance trends to identify when a part is likely to fail. This allows fleets to act early, avoiding costly breakdowns and unplanned repairs.
While implementing predictive maintenance requires the right software and analytical expertise (something that can be challenging for smaller fleets), the ROI in uptime and repair cost reduction makes it worthwhile. With the right insights, managers can prioritize issues: fixing what’s urgent, planning what can wait, and aligning everything with the next PM cycle.
Track key fleet maintenance metrics to improve performance and asset utilization
What gets measured gets managed. Fleet maintenance teams should establish key performance indicators (KPIs) to monitor efficiency and spot patterns that point to hidden problems.
Some key metrics to track include:
- Component lifespan: How many miles does each major part (e.g., tires, brakes) last before replacement?
- Between-service repairs: Do certain vehicles need attention between PM intervals? Why?
- On-road breakdown frequency: Too many incidents may indicate systemic maintenance gaps or operator issues.
- Driver inspection feedback: Daily vehicle inspection reports (DVIRs) can reveal developing issues long before diagnostics do.
When analyzed consistently, these metrics help managers identify root causes and continuously refine maintenance processes.
Strengthen technician and driver training to boost maintenance efficiency and safety
If you’re fortunate enough to have a good team, you want to retain them. With today’s vehicles packed with sensors, software, and advanced emissions systems, technicians need ongoing education to stay effective. Training programs should focus not only on diagnostic tools and repair procedures but also on technologies like AI, ADAS, and telematics integration.
Drivers, too, play a critical role as the first to notice performance changes or warning lights, serving as the fleet’s early warning system. Regular driver training builds awareness, encourages proactive reporting, and reinforces shared responsibility for keeping assets road-ready.
Transform fleet maintenance into a strategic advantage in a tightening truck market
As new-truck availability tightens and costs rise, fleets that master the art of maintaining older equipment will have a real advantage. Extending asset life cycles isn’t just about saving money; it’s about building resilience, sustainability, and operational consistency in an unpredictable market. By combining proactive maintenance, data-driven insight, and continuous training, fleets can keep older trucks performing longer and more efficiently.
About the Author
Jane Clark
vice president, member services for NationaLease
Jane Clark is vice president, member services for NationaLease. In this position, she is focused on managing the member services operation, as well as working to strengthen member relationships, reduce member costs, and improve collaboration within the NationaLease supporting groups. Prior to joining NationaLease, Jane served as area vice president for Randstad, one of the nation’s largest recruitment agencies, and before that, she served in management posts with QPS Companies, Pro Staff, and Manpower, Inc.