Common Truck Breakdowns and How to Prevent Them

For owner-operators and fleet managers, there is no sound more expensive than silence—the silence of a truck that won't start or the sudden quiet of an engine failing on I-190.

After 22 years of providing heavy-duty towing and truck repair in Sterling, MA, the team at Matthew’s Truck Service has seen every type of roadside failure imaginable. While some breakdowns are unavoidable, the vast majority can be prevented with the right knowledge and a proactive maintenance schedule.

Here are the most common reasons trucks end up on the hook and how you can stay on the road.

1. Cooling System Failures

The cooling system is the heart of your truck’s temperature regulation. A leak or a failed water pump can lead to rapid engine overheating, which can cause catastrophic damage to your cylinder heads and engine block.

• How to Prevent It: Regularly inspect hoses for cracks or soft spots and check your coolant levels before every long haul. A professional coolant flush should be part of your annual fleet maintenance to remove debris and prevent corrosion.

2. Electrical System Issues

Modern heavy-duty trucks are more reliant on electronics than ever. Most electrical breakdowns stem from three sources: the battery, the alternator, or the starter motor. In the cold Massachusetts winters, battery capacity can drop by 50%, making electrical failures even more common.

• How to Prevent It: Keep battery terminals clean and free of corrosion. Have your charging system tested before the winter season begins to ensure your alternator is providing enough juice to keep the batteries topped off.

3. Brake Failure

Brake issues aren't just a breakdown—they are a major safety hazard. Air leaks, worn brake pads, and drum damage are frequently cited during roadside inspections.

• How to Prevent It: Listen for unusual squealing or grinding and feel for vibrations when braking. Regular Brake and Suspension Safety Checks are essential to catch thinning pads or leaking air lines before they lead to a "truck-down" situation.

4. Tire Blowouts

Tire issues account for a massive percentage of roadside assistance calls. Under-inflation is the leading cause of tire failure because it creates excessive heat, leading to tread separation.

• How to Prevent It: * Check tire pressure daily with a manual gauge.
• Inspect sidewalls for bulges or cuts.
• Maintain proper alignment to prevent uneven wear.

5. Fuel System Problems

Contaminated fuel or clogged fuel filters can starve your engine, causing it to sputter or die completely. This often happens when a truck has been sitting or when switching between seasonal fuel blends.

• How to Prevent It: Change your fuel filters according to the manufacturer’s intervals—or sooner if you’re running in high-dust environments. Using high-quality fuel and additives can also prevent "gunk" from building up in your injectors.

Why Preventive Maintenance is the Best Investment

The cost of a tow and an emergency roadside repair is almost always triple the cost of a scheduled shop visit. By catching a leaking hose or a weak battery in the garage, you save money, protect your CSA score, and—most importantly—keep your delivery schedule on track.

Trust Sterling’s Heavy-Duty Experts

Whether you manage a single rig or a massive fleet, Matthew’s Truck Service & Heavy Duty Towing Inc. is here to be your partner on the road. From ASE-Certified repairs to 24/7 emergency towing, we have the experience to get you back in gear. Get in touch with us!