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SEARCHWhile repair and maintenance costs decreased considerably in 2019, the industry could see an increase in maintenance costs driven by a strong demand for trucking. Here's the maintenance you need to know from HDT's 2021 Fact Book.
Heavy Duty Trucking’s annual Fact Book is designed to provide a snapshot of the current state of the industry, where it’s been, and where it’s going. These numbers can help you in planning and benchmarking your fleet, and in telling trucking’s story to others.
Graphic: HDT
While repair and maintenance costs decreased considerably in 2019, moving from 17.1 cents per mile in 2018 to 14.3 cents per mile in 2019, the industry could see an increase in maintenance costs driven by a strong demand for trucking.
The cost per mile for repair and maintenance has increased by 39% since 2008 due to more advanced technology in trucks. On top of that, the demand for trucking in 2020 and into 2021 alone could also grow those numbers.
Repair and maintenance costs have increased 24% since 2012 — a counterintuitive increase given the record sales of new trucks and trailers. From 2012 to 2018, overall motor carrier operational costs have increased more than 11.6% — exceeding the 10.8% inflation rate for that same time period.
Source: American Transportation Research Institute
With demand driven by the essential nature of the business during the COVID-19 pandemic and the subsequent boom in the U.S. e-commerce market, maintenance costs could increase due to more miles being driven per truck, ATRI officials said in a 2020 report analyzing the operational costs of trucking.
Recent maintenance costs in the industry are of course also dependent on several factors, including fleet type and size.
Large fleets typically have their own maintenance facilities, which can mean lower costs as opposed to using outside providers for repair and maintenance.
Source: American transportation Research Institute
Repair and maintenance costs remained highest for specialized fleets in 2019 at 18.7 cents per mile. Truckload carriers reported the lowest line-item repair cost at 12.8 cents per mile on average, while less-than-truckload carriers reported about 16 cents per mile on average, according to ATRI’s report.
Repair and maintenance costs remained higher for specialized fleets than other fleets in 2019 at 18.7 cents per mile. Truckload carriers reported the lowest line-item repair cost at 12.8 cents per mile on average.
Source: American transportation Research Institute
What remains a constant is the type of repairs being made the most often.
The top components/systems that lead to roadside breakdowns across all the fleets continued to be the lighting system, powerplant, brakes and tires, according to the Technology & Maintenance Council and FleetNet America’s Benchmarking report — the same components that top the list most years.
The average cost of roadside repairs gradually increased last year, a mirror of 2019 when the average cost of a roadside mechanical repair increased to $334 in the fourth quarter, up from $317 in the third quarter and $299 in the second quarter.
Source: TMC/FleetNet Benchmarking Report
In the last five years, aftermarket parts demand for medium- and heavy-duty vehicles (Class 6-8), trailers and container chassis has grown 25%. The heavy-duty distributor lost 2 percentage points, 1 point each to the independent garage and other. The OE dealer share has held steady at nearly half of the market.
Source: MacKay & Company
This white paper examines how advanced commercial vehicle diagnostics can significantly reduce fleet downtime as heavy duty vehicles become more complex. It shows how Autel’s CV diagnostic tools enable in-house troubleshooting, preventive maintenance, and faster repairs, helping fleets cut emissions-related downtime, reduce dealer dependence, and improve overall vehicle uptime and operating costs.
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Phillips Industries’ new Cincinnati-area distribution center is now shipping aftermarket trucking parts nationwide, aiming to speed up delivery times for customers.
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Cummins used Heavy Duty Aftermarket Week (HDAW) to introduce a new brake pad platform aimed squarely at one of the aftermarket’s biggest pain points: Complexity.
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Safety, uptime, and insurance costs directly impact profitability. This eBook looks at how fleet software is evolving to deliver real ROI through proactive maintenance, AI-powered video telematics, and real-time driver coaching. Learn how fleets are reducing crashes, defending claims, and using integrated data to make smarter operational decisions.
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Fleet software is getting more sophisticated and effective than ever, tying big data models together to transform maintenance, safety, and the value of your existing tech stack. Fleet technology upgrades are undoubtedly an investment, but updated technology can offer a much higher return. Read how upgrading your fleet technology can increase the return on your investment.
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Artificial intelligence gets plenty of attention at tech shows like CES — but what does it look like in a real trucking maintenance shop? Watch what Brent Hickman has to say about how one of the largest fuel-hauling fleets in the country is using AI.
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ACC Fleet Solutions is a new offering that allows fleets to address recurring part failures with higher-performing, custom-engineered solutions developed at no up-front cost.
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In addition to suspension components, Hendrickson will highlight a range of complementary systems and technologies at HDAW 2026.
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