Fleet Longevity Guide
Looking for ways to dramatically extend the life of a semi-truck – and gain solid ground in operational efficiencies for your firm? Here are some insightful suggestions – more than 50 of them, actually – that can have a great impact on your fleet’s overall success.
Tips 01–06
By installing Ex-Guard grille guards, Ex-Guard customers have reduced their towable accidents by 80%! Learn how Ex-Guard defends your trucks’ major components – and protects your fleet’s most valuable asset – its drivers. Damaging any of the dozens of front-end components can take a truck out of service or even have it totaled. Extend the average life of your fleet by having a significant smaller number of trucks take catastrophic damage.
A semi-truck should last a minimum of 500,000 to 750,000 miles with regular maintenance and preventive care. Plus, regularly scheduled maintenance helps catch issues before they escalate. Get started with this four-step guide from Samsara.
According to the FMCSA, before operating the vehicle, drivers must inspect the vehicle and be satisfied that it is in safe operating condition. This can help prevent accidents, being cited for equipment failure (like a burned-out brake light) and ensures optimum driving performance. Fleets must ensure their vehicles are easy for drivers of all shapes, sizes and abilities to check in their pre-trips. Failure to do so could result in disastrous consequences. Check for any loose or broken body parts and any trapped debris/snow build-up that could detach while driving. Verify inspections are completed.
Follow or exceed manufacturer recommendations for oil change intervals to keep the engine in top condition and maximize fuel efficiency. As engine oil circulates through the engine, it collects dirt, metal particles and other contaminants. If left unchecked, these can cause significant damage. Weighing what type of oil is best for your fleet? Most full-synthetic oils do cost more up front, but edge out conventional oil for reduced maintenance, overall performance and fuel efficiency.
Regularly inspect and replenish engine oil, coolant, steering fluid, transmission fluid and brake fluid. Keeping these fluids topped off can help you protect major engine components, ensures compliance with emissions standards and helps improve fuel efficiency. The best fleets reward drivers that keep these topped off and/or note any wear and tear. These behaviors become habits and reinforce a culture of safety.
Regularly check brake pads, rotors and hydraulic systems for wear and proper function. Experienced drivers invest in pads before they become a liability. Don’t let brakes squeaking become a grind – changing brake pads early can prevent rotor wear damage – and replacing brake rotors is much more expensive.
Tips 07–09
Maintain proper tire inflation for safe driving, to improve tire lifespan and boost fuel efficiency. In fact, maintaining the correct tire pressure, semi-trucks and big rigs can improve their fuel efficiency by up to 3%. For long-haul truckers, this can result in significant savings and promotes more even tire wear.
Regularly rotating tires will extend their life and ensure even wear. Rotating schedules can vary depending on the type of tire, how many miles they’re certified for and driving style. Bottom line: an even tread on all tires means the driver will notice improved handling, be able to brake more safely and enjoy a smoother ride. Pro-tip: Keep an eye on your tires, as the tread on some may wear faster than others.
Ensure proper alignment to prevent uneven tire wear and handling issues. Properly aligned wheels extend tire life, improve driver handling, boost fuel efficiency and enhance driver safety. Truck alignments should generally be checked every 10,000 to 12,000 miles, or at least once a year. However, the frequency of an alignment might vary based on factors like load weight, driving conditions or steering that pulls or drifts.
Tips 10–12
Invest in quality fuel to enhance engine performance and reduce deposits. While standard #2 is the most common type of general-purpose diesel fuel, take note that both base fuels and additives used to achieve “premium” fuel status can vary widely by supplier, affecting engine wear and fuel economy. When it’s possible to choose your fuel, a potential option for a premium fuel such as Cenex® Ruby Fieldmaster® premium diesel fuel, not only offers a quality base fuel, but also includes an enhanced, multi-functional additive package.
The bottom line when it comes to fuel filters is to change fuel filters regularly to protect the engine from contaminants. But the media – the material the filter is made of – can make a big difference as well. It can range from cellulose-based filters to ones that utilize specialized multi-stage synthetic media to effectively remove contaminants and water from the fuel. Other factors to consider are choosing the correct filter size, the micron level (the size of particles your filter can block) and a brand that conforms to the original equipment manufacturer. Also, keep in mind that fuel quality – and the amount you’re burning – can affect how often you need to change the filters. The weather can also factor into the service life of a filter, with diesel fuel gelling and waxing at lower temperatures.
Commercial vehicles continue to add more electrical systems, with the use of mulitplexed control modules and driver assist systems, just to name a couple enhancements. That’s why it’s more important than ever to ensure technicians are thoroughly trained on the latest diagnostic tools and current on their continuing education courses. An incorrect diagnosis can send you down the wrong repair path, not to mention waste precious time spent on unnecessary maintenance.
Tips 13–15
Teach fuel-efficient driving habits to minimize wear and improve fuel economy – and have them incorporate these steps into their daily driving routine. One approach is “less is more:” less idling and less speeding. Another tip is to monitor and keep tire pressure at the correct amount, which helps improve fuel efficiency. Also employ more route planning to avoid delays and detours, as additional aerodynamics, such as adding side skirts, trailer tails and aerodynamic mirrors, to improve fuel efficiency.
Encourage drivers to maintain proper speeds to reduce engine strain, improve fuel efficiency and avoid collisions. Other tips include using adaptive speed control, follow at a safe distance and slowing down before curves to prevent cargo shifts and rollovers.
Encourage drivers to turn off the engine during extended stops to save fuel, reduce engine wear and lessen their impact on the environment. For example, did you know that idling a Class 8 truck can consume up to almost one gallon of fuel per hour? This can add up to thousands of gallons of wasted fuel per year. An APU (auxiliary power unit) can be installed so drivers don’t have to keep the engine idling during rest times, and allows them to run a heater, charge batteries, etc., without sacrificing fuel economy.
Tips 16–19
Use OEM or high-quality aftermarket parts to ensure durability. OEM parts are generally considered the best option for parts in a truck because they fit and perform well, are made with high-quality materials and come with a warranty. And while it might be tempting (and less expensive) to invest in foreign parts, you run the risk of purchasing potential imitations that lack quality or consistency, not to mention more costly tariffs you may have to pay for them in the future.
During inclement conditions – rain, snow, sleet, you name it – it’s critical for drivers to always have good visibility. In fact, 90% of driving decisions are based on vision. Dirty or worn blades can leave streaks and smeared windshields, reducing visibility, jeopardizing driver safety and increasing the chance for accidents. Consider investing in durable, high-quality wiper blades and see the difference.
Don’t let aerodynamics be a drag on your rig’s engine performance and fuel economy. Among the leading offenders when it comes to wind resistance is the gap between the tractor and the trailer, which can produce 25 % of the overall drag. Install aerodynamic features like fairings and side skirts to improve fuel efficiency. When traveling at higher speeds, opt for running the air conditioner versus having your windows rolled down, which changes the contours of your truck – and impacts its aerodynamics. Make sure your tires are not underinflated, which creates more contact with the road, resulting in more friction and drag. And watch your speed – as it increases, the drag force increases exponentially due to the additional air.
Modern transmissions, such as automated-manual transmissions, shift-by-wire technology, power-shift transmissions and electric axle transmissions, can improve performance and fuel economy. These systems offer you different options for your fleet, based on your specific applications and operational requirements.
Tips 20–22
Keep in mind that your trucks are seen by thousands of drivers each day, and a freshly washed truck looks sharp – and professional. In addition, keeping your rig’s exterior clean extends the life of it by preventing rust and corrosion. Also, a clean truck has less wind resistance, which means better fuel efficiency. And finally, a clean truck is less likely to shed dirt and debris which could endanger other drivers.
Based on Hours of Service rules, drivers can drive up to 11 hours a day. That’s a lot of time spent in your over-the-road office! Use seat covers and floor mats to protect against wear and tear. Keeping cabs and living spaces clean and uncluttered help drivers be more focused on the road – and less on the mess.
Address any dents, scratches or rust spots quickly to prevent further deterioration. Even minor damage could be a tell-tale sign of a bigger issue, like a fluid leak, structural damage or electrical issues. Plus, inspecting your trucks regularly – and tracking them – can help you protect against liability issues down the road.
Tips 23–24
Check out these eight essential tips, including equipping trucks with winter tires, checking antifreeze levels and inspecting the heating system. Also, plugging in an engine block heater (usually an option on older truck models) a few hours before your trip can help your truck’s batteries last longer by reducing the need for cranking, as well as reduce engine wear by improving oil circulation. Once on the road, keep the fuel tank full, practice winter driving techniques, make sure your emergency kit is stocked and phone is fully charged.
From the cooling system to tire pressure, summer driving can put additional strain on your engine and major components, leading to potential overheating and tire blowouts. Here’s a top 10 list of things to check before you hit the road so your truck can handle the heat.
Tips 25–26
Keeping these records is not just a good idea to protect the driver and their fleet, it’s required: The FMCSA requires drivers to keep accurate and updated records of all maintenance and repairs for better tracking and accountability. These records include a maintenance schedule (including the last service and when the next service is due), reports of all inspections, repairs, and maintenance, copies of roadside inspections and Daily Vehicle Inspection Reports.
Regulations within the trucking industry are always evolving. Review the industry changes published for 2025, including the FMCSA’s new registration system, and continue checking current FMCSA guidance to avoid unnecessary compliance issues or fines.
Tips 27–28
One recent study found that fuel costs make up 24% of the total average marginal costs within the trucking industry. It’s a significant overhead cost, which is why it’s more important than ever to track fuel usage and identify inefficiencies in fuel consumption. Programs like OptimoRoute can help you analyze route data and provide actionable solutions.
When your drivers are behind the wheel, they impact everything from fuel consumption and delivery times to your fleet’s safety scores and reputation. So, addressing and improving driver behavior is critical to your organization’s success. It’s a balance between engaging the human element (impactful training for drivers and listening to their feedback) and employing technology, like telematics and state-of-the-art ELD to monitor driver habits, analyzing trends and looking for potential problem areas regarding route selection and fuel-efficient driving.
Tips 29–30
When extreme weather hits, your truck breaks down or an accident happens, a fully stocked emergency kit can literally be a lifesaver. Here’s an essential list of emergency must-haves, including items like flares, first aid supplies and basic tools each truck should carry for the unexpected.
The Federal Highway Administration estimates that a truck driver in the United States drives long-distance trucks over 100,000 miles yearly. With that much time on the road – and with millions of vehicles alongside them – chances are your drivers will come upon an emergency situation. Have them regularly practice emergency procedures to ensure preparedness and comply with FMCSA regulations.
Tips 31–32
Today, a typical semi-truck can last up to 750,000 miles (or more!). The optimal replacement plan for a semi-truck fleet depends on many factors, including the age of the truck, its maintenance history and type of usage. Keep in mind that older trucks will usually require more costly repairs, so preventative maintenance is key – and also have a plan for timely replacements of aging trucks to minimize downtime and repair costs.
There are many pros and cons for maintaining older trucks versus purchasing new ones. Start with a cost-benefit analysis. You’ll have to weigh several factors, including your budget, the mileage your trucks cover each year and their current condition. For more insight on keeping your old fleet vs. investing in new, check out this blog from Optym, a company focused on bringing efficiency to transportation through optimization and AI.
Tips 33–34
When drivers feel heard, they’re more engaged. And higher engagement means greater employee retention. Ensure your drivers have an open line of communication with their leaders and peers, where they can report issues and concerns without judgment or penalty. To help drivers feel connected, check out these driver engagement and retention tools from tenstreet.
Implement reward programs for drivers who maintain safe driving records. The benefits of a driver safety program are numerous, but the biggest potential advantages include reduced accidents, lower insurance premiums and improved driver behavior. Online driver safety courses, like the ones offered by Driving Dynamics and DriveSafe Online, provide many instruction options and are mobile friendly for drivers on the go.
Tips 35–36
Also referred to as fleet tracking or GPS vehicle tracking, telematics employs real-time monitoring and data collection regarding vehicle performance, route optimization and driver behavior. By using telematics, you can minimize fuel waste, improve fleet safety and proactively identify vehicle maintenance-related issues before they cause breakdowns or other issues, according to this DispatchTrack.com article.
Tracking the maintenance schedule for an entire fleet, along with planning for repairs and ordering parts can be daunting, to say the least. Using fleet maintenance management software helps collate all the data and can project your fleet’s ongoing maintenance needs. These highly intuitive software programs can improve fuel management, ensure compliance with safety standards and reduce operating costs. A system from Fleetio, for example, uses an online dashboard approach to help you manage everything from inspections to PM schedules, parts inventory to work orders.
Tips 37–38
Keep in mind that the EPA’s regulations for model year 2027 and later are expected to be the most significant commercial-trucking emissions regulations since 2007. Get a head start on eco-friendly operating procedures with some changes you can make right now, including optimizing routing, considering alternative fuel options, proactively maintaining and upgrading your fleet and rewarding efficient drivers.
You can have a lasting, positive impact on the environment by reducing the number of parts (e.g., tires) that would potentially end up in landfills or fluids such as antifreeze or engine oil disposed of improperly. Here’s some additional info from the EPA about managing, reusing and recycling oil. Also consider purchasing quality recycled or used parts as opposed to purchasing new parts. This option can save truck owners approximately 50% without sacrificing the life expectancy of the part, according to Vander Haag’s Inc., a leading commercial truck salvage company.
Tips 39–40
From ensuring driver safety to monitoring the payload they carry, implementing an effective fleet risk management strategy – and sticking to it – is crucial for your fleet for several reasons. Identifying and addressing potential risks can help reduce collisions, save lives and avoid vehicle downtime. Ultimately, it can help avert lawsuits and potential financial and reputational damage. For more information and best practices, read this fleet risk management guide from Geotab.
Regularly evaluate coverage to ensure adequate protection for the fleet, keeping in mind factors like FMCSA requirements and cargo type. Also, find the appropriate limits for your commercial truck insurance, compare policies from different providers and get one that best matches your protection needs. And here’s a couple of quick pro tips from Motive’s guide to fleet and truck insurance to help reduce your premiums: attain excellent SAFER scores and improve driver performance.
Tips 41–42
Fleet metrics can help you increase production, decrease wasteful spending, make more informed decisions and better manage both human resources and company assets. You can do this by reviewing data on KPIs such as fuel consumption, maintenance costs and driver performance. But the real key to fleet performance metrics is sharing the results with everyone in the organization, from key decision makers to drivers, then taking actionable steps based on the information you gather.
Benchmarking in the trucking industry involves comparing your fleet’s performance against industry standards and similar fleets. It can help you identify strengths and weaknesses, learn best practices, set performance goals, improve operations and reduce transportation risk. The process involves analyzing key performance indicators (KPIs) and metrics related to costs, transportation times, storage and other relevant factors. Some organizations that provide benchmarking services for the trucking industry include DAT iQ, Liberty Mutual Insurance Company and the National Motor Freight Traffic Association.
Tips 43–44
Truck drivers face unique health challenges, with long hours, stress and poor sleep affecting their well-being. In fact, over half of U.S. truck drivers are overweight or obese, leading to a higher risk of chronic pain, depression and more. This takes a toll on their mental and physical health, which in turn, impacts the industry. Create a positive work culture along with opportunities to develop healthy habits to enhance driver performance and reduce absenteeism. Review employee benefits to ensure they are adequately meeting their mental and physical health needs – and provide them outlets and resources for assistance. For example, a great wellness-focused resource is the Driver Health and Wellness Hub on American Trucking Associations site.
Since drivers can typically drive up to 11 hours a day – or more in some cases – it means prolonged pressure on the neck, back and feet. Educate drivers on proper lifting techniques and seat adjustments, including adequate lumbar support, to reduce the impact on their bodies and prevent injuries. Proper ergonomics can help drivers reduce pain, avoid long-term physical issues, reduce fatigue and increase their safety.
Tips 45–46
Gain an edge for your fleet – by offering growth opportunities for your drivers and enhancing their skills – with regular training on safety, maintenance techniques and new technologies. Ongoing training programs for drivers also include CDL refresher courses, regulatory and compliance courses, classes that offer advanced certifications and even online college courses they can take while on the road.
Take time to share knowledge and industry updates on effective maintenance, operational strategies, driver safety and changes in industry regulations. By investing in training your fleet in industry best practices, it can boost the potential revenue for your company by increasing operational efficiency, not to mention the retention of your drivers. A great place to start is the FMCSA home page, which offers several informed and reliable resources regarding regulatory updates, safety requirements and accident statistics.
Tips 47–49
Understanding the costs associated with trucking – and constantly tracking and evaluating any fluctuation in operational expenses – is crucial for fleets to effectively manage their operations and maintain financial stability. This August 2024 report from Foley breaks down all the factors, from fuel expenses to maintenance costs, from tolls to finding loads, as well as some hidden expenses, that can significantly impact your fleet’s bottom line.
Installing APUs, while a somewhat substantial initial investment, uses much less fuel than an idling tractor engine, which can save thousands of dollars per year. Plus, less running time means reduced engine wear and tear, less frequent maintenance and lower maintenance costs. And if you choose to use an EPU (electric auxiliary power unit), consider using solar panels, which can be effective in charging the batteries, even in remote locations.
Social responsibility in truck fleets means adopting a set of practices that can help your company be more ethical, improve the environment and support the community. Some specific tactics include reducing emissions, engaging in community and volunteer initiatives, ensuring fair labor practices and showing commitment to stakeholders. Companies can also participate in an EPA program called SmartWay that helps companies integrate freight into their sustainability journey.
Tips 50–51
Employing this digital tool allows you to ditch the spreadsheets and paper-based processes. FMS can help you streamline operations, scheduling and maintenance tracking. More specifically, you can use this tool to complete tasks like tracking vehicle location, driver behavior and equipment performance. Using fleet management software can also help you analyze fuel usage and forecast service needs. To learn more about the capabilities of FMS, check out FMS providers such as Fleetio or Autofleet.
Don’t let your company’s policies and procedure manuals collect dust. Review them on a periodic basis to ensure they’re up to date and reflect best practices in fleet management. Ensure that new drivers and experienced ones alike are familiar with them, know where to find them and put them into practice every time they climb behind the wheel. Because if an accident happens, a truck breaks down unexpectedly or a driver infraction occurs, the first question your company will probably be asked is, “Were you following procedures?” A solid understanding and adherence to company policies will empower your employees to most likely answer with a resounding “yes.”
Protect the Front End
Explore current Ex-Guard protection for semi-truck fleets, or connect with a local dealer for fitment and pricing support.
* Ex-Guard is an independent manufacturer of high-quality after market grille guards. Ex-Guard and the Ex-Guard® line of products are not endorsed, associated with, or otherwise sponsored by Navistar Inc., Paccar Inc., Daimler Trucks North America, Hino Motors Ltd., Volvo Trademark Holding AB or Mack Trucks Inc. Any third party trademarks referenced by Ex-Guard whether in logo form, name form, or otherwise remain the property of their respective holders. All information contained is reference purposes only and does not imply a recommendation or partnership for products and services.
