What Fleet Managers Need to Know About the Most Common Light-Duty Vehicle Repairs

Keeping your work vehicles running well means regularly checking them so they don't break down unexpectedly, need last-minute repairs, or disrupt schedules. Instead of just waiting for things to break, create a routine maintenance schedule based on the manufacturer's advice and how much the vehicles are used. Save money by analyzing data and addressing common issues early on.

Smart maintenance planning keeps things running smoothly, ensures your vehicles are available, and gives your business a competitive advantage. Kooner can help schedule routine maintenance and organize operations so you can perform check-ups and avoid costly emergencies. Using data helps you manage your fleet budget, plan for new vehicles, and choose the best models and parts.

Most Common Light-Duty Vehicle Repairs Impacting Fleets

The light-duty vehicle is at the core of many fleets; however, it falls prey to unique mechanical issues that fleet managers should be aware of. A recent Vehicle Fleet Maintenance Report reveals that preventable mechanical failures represent nearly 37% of all roadside breakdowns, and proper maintenance could lead to an increased lifespan of vehicles up to 40%.

Let's take a look at the repairs that fleet managers consistently struggle with on a national level.

Brake System Failures

Brake system repairs are often at the top of the list of needed fleet maintenance and repairs. The constant stop-and-go motion of delivery and service vehicles takes a toll on brake systems, especially in urban settings where one driver can make 100+ stops daily.

Look out for:

• Wear on brake pads and rotors

• Brake fluid leaks

• Master cylinder failure

• Caliper binding

• Issues with the ABS system

Issues related to braking systems affect more than safety; they often relate to operational impact. When managers have to call for an unscheduled emergency roadside repair, companies lose an average of $760 per occurrence in repair costs, lack of productivity, and impact on customers. A transportation study conducted by Michigan State University found that fleets with proactive brake management systems had an overall reduction of 69% in brake-related roadside incidents.

Electrical System Issues

Today’s complex electrical systems are deeply integrated within today’s light-duty fleet vehicles, as they manage vehicle performance as well as driver assist capabilities. Battery failure remains the single greatest contributor to truck roadside assistance calls, especially in temperature extremes.

Other electrical problems that are prevalent include:

• Malfunctioning alternators

• Failed starter motors

• Wiring harness deterioration

• Problems with electronic control modules

• Sensor failure impacting multiple systems

Testing for electrical-related problems with a proactive approach is one of the most affordable and leveraged approaches fleet management can consider in its fleet management strategy. A proactive approach to testing and failure management could help mitigate electricity-related failures on the roadside by up to 65%. More fleet managers are now using quarterly site electrical system diagnostics, which can identify potential failures before drivers are halted by failure.

Fluid Related Failures

According to information from the Commercial Fleet Reliability Index, fluid leaks and fluid-related issues comprise approximately 22% of all light-duty fleet repairs. Having a robust fleet maintenance and repair plan that has fluid management at its core can significantly impact the number of fluid leaks and related repair incidents across that fleet.

Critical fluids that need to be checked include:

• Engine oil (check level AND condition)

• Transmission fluid (especially for vehicles that primarily operate in stop-and-go conditions)

• Power steering fluid

• Coolant (and seasonal adjustments for concentration changes)

• Differential fluid

• Brake fluid (which absorbs moisture over time)

When fleet systems break down, you often need emergency roadside assistance for rigs, particularly if they're stuck way out there or after hours. Interestingly, fluid problems can jump up to 40% during bad weather, according to the North American Council for Fleet Efficiency.

Issues with the Fuel System

Fuel system issues can be especially difficult because symptoms generally show up intermittently prior to a complete failure. Today's fuel systems are required to deal with fluctuating fuel quality and strict compliance with emissions.

Here are some common issues:

• Fuel pumps (middle of an expensive trip, payload got uncomfortable, strange noise)

• Clogged injectors resulting in poor running and stalling

• Contaminated fuel reduces running, performance, and acceleration

• The pressure regulator stops the flow of the fuel

• Emission control systems require replacement due to the "Check Engine" light

If you have a capable truck management firm working for you, your technicians will see the early warning signs before they grow into major repairs or roadside emergencies. Fuel system issues often have diagnostic challenges that need special equipment and competency.

Tire Issues

Tires, like fuel system problems, are predictable in nature but are still frequently overlooked as a cause of fleet downtime. In addition to the flat tires are issues such as:

• Improper inflation (under and over)

• Alignment issues are causing separate wear patterns

• Suspension components wearing to cause handling issues

• Uneven tread wear that may also be suggesting other mechanical issues

• Seasonal changeovers for tires depending on location

Not only do these issues lead to emergency roadside assistance, but they are also detrimental to fuel economy. With proper protocols for tire management, fleets can save 3-7% in fuel and extend tire life in some cases by 25%. Tire pressure monitoring systems now provide real-time notifications

Preventive Measures

Increasingly, fleet managers are shifting away from reactive maintenance to predictive maintenance. Comprehensive fleet management solutions allow operations to predict and eliminate many routine light-duty vehicle repairs.

Examples of some good practices include:

• Schedule preventive maintenance based on both mileage and time intervals

• Use telematics data to track early indicators of potential mechanical failures

• Have drivers trained to observe and report potential issues well before a problem occurs

• Develop relationships with reputable truck roadside assistance in emergencies

• Implement digital inspection processes that track the degradation of components over time

• Analyze repair data to learn the averages for patterns specific to your fleet usage cycles

The financial case for preventive maintenance is compelling: fleet operations that have implemented systematic prevention programs have reported an average reduction in maintenance costs of 15-30% in the first year alone.

Seizing the Future of Fleet Maintenance

By being aware of the most common repair issues, fleet managers are prepared to choose a maintenance program, replacement cycles, and vendor relationships. The best fleet operations use a mix of their own internal maintenance capabilities, partnered with specialized service providers. Addressing those common repair issues through a comprehensive fleet management solution, your organization will reduce downtime, avoid costs related to maintenance, and increase operational reliability.

Allow yourself to speak with experienced professionals who understand fleet maintenance and develop ways to customize your operations to not only fix your vehicles but also keep your business moving. The difference between a good maintenance program and an excellent maintenance program is almost always the partnerships that are behind your operation.

Partner with fleet experts in Kooner today!