Truck Maintenance Schedule and Costs: What Owner Operators Actually Pay in 2026

You just bought your truck. The dealer says "maintenance is simple – just follow the schedule."

Then you get your first PM bill for $1,200. Your second month, a sensor goes bad: $800. Month three, you need tires: $3,500.

Nobody warned you about THIS.

Let me show you the real maintenance schedule and what it actually costs. Not the dealer's optimistic estimates, but what owner operators are paying in 2026.

The PM Schedule Every Owner Operator Needs to Know

Different manufacturers have different schedules, but here's what you're looking at:

Freightliner/Western Star PM Intervals

A-Service (every 15,000 miles):

• Oil and filter change
• Grease chassis (20-25 points)
• Visual inspection of brakes, belts, hoses
• Check fluid levels
• Tire rotation (if needed)
• Cost: $400-$600

B-Service (every 30,000 miles):

• Everything in A-Service PLUS:
• Fuel filter replacement
• Detailed brake inspection
• Exhaust system check
• Suspension inspection
• Coolant system check
• Cost: $800-$1,200

Additional intervals:

• Engine air filter: Every 90,000-100,000 miles ($150-$250)
• Air dryer filter: Every 150,000 miles ($100-$200)
• Transmission service: Every 100,000-150,000 miles ($600-$1,000)

Sources: TEC Equipment PM Schedule, Freightliner Preventive Maintenance

Kenworth/Peterbilt PM Intervals

PM-A (every 12,500 miles):

• Oil and filter change
• Grease job (20-25 fittings)
• Basic inspection
• Top off fluids
• Cost: $450-$700

PM-B (every 25,000 miles):

• Everything in PM-A PLUS:
• Fuel filters
• Brake adjustment and inspection
• Full chassis inspection
• DEF system check
• Cost: $900-$1,400

Paccar engines (MX-13):

• Oil changes: Every 50,000 miles with semi-synthetic ($500-$700)
• Fuel filters: Every oil change
• Coolant service: Every 300,000 miles ($800-$1,200)

Cummins engines (X15):

• Oil changes: Every 50,000 miles ($500-$700)
• Fuel filters: Every 25,000 miles
• Valve adjustment: Every 300,000-400,000 miles ($800-$1,500)

Sources: Kenworth Truck Maintenance, TruckersReport PM Schedule

What Labor Actually Costs in 2026

Here's the reality of shop rates:

National average: $190/hour (up from $125/hour three years ago)

Regional breakdown:

• Western US: $200-$220/hour
• Midwest: $170-$190/hour
• South: $160-$185/hour
• Northeast: $185-$210/hour

Why the jump? Technician shortage. There aren't enough diesel mechanics, so shops charge more.

What this means for you:

Simple A-Service (2 hours of labor + parts):

• Labor: $380-$440
• Oil (10-13 gallons): $65-$90
• Filter: $40-$60
• Grease/misc: $20-$30
• Total: $505-$620

Complex B-Service (4-5 hours of labor + parts):

• Labor: $760-$950
• Oil and filters: $105-$150
• Fuel filter: $80-$120
• Other parts/fluids: $100-$150
• Total: $1,045-$1,370

Sources: Labor Cost Trends FreightWaves, AAA Labor Rates 2026

Annual Maintenance Budget by Mileage

Here's what to actually budget based on how many miles you run:

100,000 miles per year (regional/local)

Scheduled maintenance:

• PM-A services (8 times): $4,000-$5,600
• PM-B services (4 times): $3,600-$5,200
• Annual total: $7,600-$10,800

Unscheduled repairs (average):

• Sensor failures, small repairs: $2,000-$4,000
• One medium repair: $1,500-$3,000
• Total unscheduled: $3,500-$7,000

Tires:

• Drive tires (2): $1,400-$1,800
• Trailer tires (2-4): $1,200-$2,400
• Total tires: $2,600-$4,200

Annual total: $13,700-$22,000 Cost per mile: $0.14-$0.22

150,000 miles per year (OTR)

Scheduled maintenance:

• PM-A services (12 times): $6,000-$8,400
• PM-B services (6 times): $5,400-$8,200
• Annual total: $11,400-$16,600

Unscheduled repairs:

• Higher mileage = more breakdowns: $5,000-$10,000

Tires:

• Drive tires (4-6): $2,800-$5,400
• Trailer tires (4-8): $2,400-$4,800
• Total tires: $5,200-$10,200

Annual total: $21,600-$36,800 Cost per mile: $0.14-$0.25

Sources: Schneider O/O Maintenance Costs, International Used Truck Center

What Owner Operators Actually Spend (Real Forum Data)

TallJoe (8 years O/O, 91,484 miles in 2021): "Maintenance and repairs was the highest ever too. Most of it is nickel and dime. Buy the time you fix or replace an N-th part on the truck, the parts you replaced at first...will start giving out again."

• Cost per mile: $1.42 (total operational cost excluding wages)

Long FLD (100,000 miles in 2021): Maintenance & Repairs: $16,755.76

• Cost per mile for maintenance: $0.17
• Total operational costs: $106,688.47

uncleal13 (Road Train Member): "When I was doing five axle it was $800 a month. Now I'm doing eight axle, it's pretty close to $2,000 a month including trailer and tires."

• 5-axle monthly: $800 ($9,600/year)
• 8-axle monthly: $2,000 ($24,000/year)

HopeOverMope (Road Train Member): "Average annual maintenance cost for O/O's across the board are about 5k - 25k"

x1Heavy (Road Train Member): "If a nice engine in total costs about 40,000...you will want a new engine fund to be at least that much in say... 5 years. Call it 800 dollars a month."

Sources: TruckersReport: O/O Costs 2021, TruckersReport: Monthly Maintenance Budget

The Big Repairs You Need to Budget For

These are the costs that wipe out unprepared owner operators:

Engine Repairs

DEF/SCR system failure:

• Cost: $4,000-$10,000
• When: Usually 400,000-600,000 miles
• Signs: Check engine light, derating, poor fuel economy

EGR cooler replacement:

• Cost: $2,500-$4,500
• When: 300,000-500,000 miles
• Signs: Overheating, coolant loss, white smoke

Turbocharger replacement:

• Cost: $2,000-$4,000
• When: 400,000-600,000 miles
• Signs: Loss of power, black smoke, oil leaks

Full engine overhaul:

• Cost: $20,000-$35,000
• When: 800,000-1,200,000 miles
• Alternative: Remanufactured engine $25,000-$40,000

Transmission Repairs

Clutch replacement (manual):

• Cost: $2,500-$4,000
• When: 400,000-600,000 miles
• Signs: Slipping, hard shifts, burning smell

Transmission overhaul/replacement:

• Cost: $8,000-$15,000
• When: 500,000-800,000 miles
• Signs: Slipping gears, delayed engagement, grinding

Brake System

Complete brake job (per axle):

• Cost: $300-$900
• When: Every 100,000-150,000 miles
• Includes: Pads, drums/rotors, adjustment

Air disc brake overhaul:

• Cost: $5,000 (all axles)
• When: Every 200,000-300,000 miles

ABS module replacement:

• Cost: $600-$2,000
• When: As needed (sensor failures common)

Suspension and Steering

Air ride suspension repair:

• Air bags (each): $200-$400
• Complete system: $2,000-$4,000

Steering system:

• Tie rod ends: $300-$600
• Steering box rebuild: $800-$1,500
• Complete overhaul: $2,500-$4,000

Sources: BFS Fleet Service Breakdown, Mann's Wrecker Most Expensive Repairs

Monthly Maintenance Budget Breakdown

Let's get specific. Here's how to budget month by month:

Steady-State Maintenance (Every Month)

Reserve for scheduled PM:

• Running 12,500 miles/month: $500-$700
• Running 10,000 miles/month: $400-$600
• Running 7,500 miles/month: $300-$500

Reserve for unscheduled repairs:

• New truck (under 300K miles): $200-$400/month
• Mid-life truck (300K-600K): $500-$800/month
• High-mileage truck (600K+): $800-$1,500/month

Tire reserve:

• $300-$500/month
• Covers gradual replacement of all tires

Total monthly reserve:

• New truck: $1,000-$1,600/month
• Mid-life truck: $1,200-$1,900/month
• High-mileage truck: $1,400-$2,500/month

The "Oh Crap" Fund

Beyond monthly reserves, you need a separate emergency fund:

Minimum emergency fund: $10,000

This covers:

• Transmission failure on the road ($8,000-$15,000)
• Major tow bill ($500-$2,000)
• Hotel while truck is down ($150-$300/night)
• Rental truck if you need to keep running ($250-$400/day)

Owner operator quote: "The minimum you should shoot for is $2,500 in your reserve for licensing and $15,000 in maintenance." – reverendhandy, TruckersReport

Build your emergency fund: "Put 15% of every load away. If that's high, start with 10%." – reverendhandy

If you gross $10,000/week:

• 10% = $1,000/week = $4,000/month
• 15% = $1,500/week = $6,000/month

Takes 2-3 months to build a $10,000 cushion at 15%.

Sources: TruckersReport: Monthly Maintenance Budget

New Truck vs Old Truck Maintenance Costs

New Truck (0-250,000 miles)

Annual maintenance: $8,000-$12,000

What you pay for:

• Scheduled PMs only
• Occasional sensor replacement
• Tires
• DEF fluid (monthly)

What warranty covers:

• Engine failures
• Transmission issues
• Most major component failures

Monthly budget: $700-$1,000

Pros:

• Predictable costs
• Minimal downtime
• Warranty coverage

Cons:

• Still paying truck payment ($2,500-$3,500/month)
• Expensive dealer service

Mid-Life Truck (250,000-600,000 miles)

Annual maintenance: $15,000-$25,000

What you pay for:

• Scheduled PMs
• More frequent repairs
• DPF regeneration issues
• Sensor failures (common)
• Clutch/brake work starting

No warranty protection

Monthly budget: $1,250-$2,100

Pros:

• Truck might be paid off
• Lower overall operating cost than new + payment

Cons:

• Unpredictable repair costs
• More downtime
• Stress of unexpected bills

High-Mileage Truck (600,000+ miles)

Annual maintenance: $20,000-$35,000

What you pay for:

• All scheduled PMs
• Major component replacements starting (turbo, injectors)
• Transmission/clutch likely needed
• Suspension work
• Possible engine overhaul

Monthly budget: $1,700-$3,000

Pros:

• Truck is paid off (hopefully)
• You know this truck inside and out

Cons:

• Something breaks every month
• Risk of catastrophic failure
• Hard to plan cash flow

PM Checklist: What Should Be Checked Every Time

Every PM Service Should Include:

Engine:

• Oil and filter change
• Check for leaks (oil, coolant, fuel)
• Belt condition and tension
• Turbo operation (no unusual noise)
• Air filter restriction level
• DEF system check

Transmission:

• Fluid level and condition
• Check for leaks
• Clutch operation (manual)
• Shift quality (automated)

Brakes:

• Lining thickness measurement
• Drum/rotor condition
• Air system pressure test
• Slack adjuster operation
• Brake chamber inspection

Suspension:

• Air bag condition
• Leaf spring condition
• Shock absorber leaks
• Torque rod bushings
• U-bolt torque

Tires:

• Tread depth (minimum 4/32" steer, 2/32" drive)
• Inflation pressure
• Unusual wear patterns
• Sidewall damage

Lights and Electrical:

• All lights functioning
• Battery voltage and condition
• Alternator output
• Wiring damage

Frame and Body:

• Frame cracks
• Crossmember condition
• Fifth wheel operation
• Fuel tank mounting
• Air tank drains

Sources: UTI Diesel Maintenance Checklist, AltLINE Semi-Truck Maintenance

DIY Maintenance vs Shop Work: The Real Cost Difference

What You Can Do Yourself

Oil change (if you have the space and tools):

• DIY cost: $100-$150 (oil + filter + disposal)
• Shop cost: $400-$600
• Savings: $250-$450
• Time: 1-2 hours

Air filter replacement:

• DIY cost: $80-$150 (filter)
• Shop cost: $150-$250
• Savings: $70-$100
• Time: 15 minutes

Grease job:

• DIY cost: $30-$50 (grease)
• Shop cost: $100-$200 (included in PM)
• Savings: $70-$150
• Time: 30-45 minutes

Pre-trip inspection (daily):

• DIY cost: $0
• Catches problems early = Savings: Thousands in avoided breakdowns
• Time: 15-20 minutes

Annual DIY savings potential: $2,000-$4,000 if you do all your own basic maintenance.

What You Shouldn't DIY

Brake work:

• Improper adjustment = accident liability
• Requires special tools
• DOT inspection implications
• Use a shop

Transmission work:

• Highly specialized
• Expensive mistakes possible
• Requires diagnostic tools
• Use a shop

Engine internal work:

• Beyond oil changes, leave it to pros
• Warranty implications if done wrong
• Use a shop

Emissions system:

• DEF/DPF/SCR work requires scan tools
• EPA violations possible
• Use a shop

How to Cut Maintenance Costs Without Cutting Corners

1. Preventive Maintenance Actually Saves Money

Example: $600 oil change every 50,000 miles vs $25,000 engine overhaul at 600,000 miles

Skipping oil changes shortens engine life from 1,000,000+ miles to 400,000-600,000 miles.

The math:

• 12 oil changes over 600,000 miles: $7,200
• Engine overhaul at 600,000 miles (from neglect): $25,000
• Total cost of neglect: $32,200

vs.

• 20 oil changes over 1,000,000 miles: $12,000
• No engine overhaul needed
• Total cost with maintenance: $12,000

Savings: $20,200

2. Shop Around for Non-Emergency Repairs

PM at dealer:

• Cost: $1,200-$1,500
• Advantage: OEM parts, trained techs
• Disadvantage: Premium pricing

PM at independent shop:

• Cost: $800-$1,100
• Advantage: 30-40% savings
• Disadvantage: Variable quality

PM at truck stop chain (Love's, TA, Pilot):

• Cost: $900-$1,200
• Advantage: Nationwide, 24/7 availability
• Disadvantage: Quality varies by location

Annual savings with independent shop: $2,000-$4,000

3. Buy Parts Online for Non-Urgent Repairs

Example: Sensor replacement

At shop:

• Parts markup: 30-50%
• Labor: $190/hour × 1 hour
• Total: $400-$500

DIY with online parts:

• Sensor cost: $80-$120 (online)
• Your time: 30 minutes
• Total: $80-$120

Savings: $280-$380

What works online:

• Filters (air, oil, fuel)
• Sensors
• Belts and hoses
• Light bulbs
• Wipers

What doesn't:

• Emergency parts (can't wait for shipping)
• Parts you're not sure about (wrong part = downtime)

4. Join a Maintenance Program

Some truck stops and chains offer programs:

Love's Fleet Care:

• Discounted PM services
• Nationwide network
• Pre-negotiated rates

TA/Petro RoadSquad:

• Flat-rate PMs
• Points programs
• Fuel discounts

Savings: 10-20% on scheduled maintenance

5. Track Everything

Why tracking saves money:

You can identify patterns:

• "My truck eats serpentine belts every 150,000 miles" (stock up when you see a deal)
• "I spend $600 on sensors annually" (budget for it, don't panic)
• "DEF costs me $80/month" (factor into rate negotiation)

Apps and tools:

• Simply Fleet (free)
• Fleetio (paid, more features)
• Good old Excel spreadsheet

Tracking also helps at tax time – maintenance is deductible.

Red Flags: When to Take It to a Shop Immediately

Don't try to limp along with these issues:

Engine:

• Check engine light with derating
• Sudden loss of power
• Unusual noises (knocking, grinding)
• Coolant in the oil or oil in the coolant
• Excessive blow-by

Transmission:

• Won't go into gear
• Slipping under load
• Grinding or clunking
• Fluid leaking

Brakes:

• Soft pedal
• Brake warning light
• Pulling to one side
• Grinding noises

Steering:

• Excessive play in wheel
• Hard to turn
• Pulling without brake input

Trying to save money by ignoring these = bigger bills later.

Maintenance Schedule by Component

Here's when to expect major component work:

0-300,000 Miles

• Routine PMs only
• Occasional sensor replacements
• Tire replacements (150,000-200,000 miles)
• First clutch (if manual, around 250,000-300,000)

300,000-600,000 Miles

• First major EGR/DEF system work (400,000-500,000)
• Turbocharger replacement possible (400,000-600,000)
• Transmission service getting critical
• Suspension components wearing (bushings, air bags)
• Second clutch replacement

600,000-900,000 Miles

• Engine overhaul decision point (rebuild vs replace)
• Transmission overhaul likely
• Third clutch replacement
• Extensive suspension work
• Possible rear differential work

900,000+ Miles

• Everything is wearing out
• Multiple systems need attention
• Decision point: Keep fixing or replace truck?

The Monthly Maintenance Budget Template

For a truck running 120,000 miles/year:

Category	Monthly Amount	Annual Total
Scheduled PM	$600	$7,200
Unscheduled repairs	$500	$6,000
Tires	$400	$4,800
Emergency fund contribution	$500	$6,000
Total Monthly	$2,000	$24,000

Cost per mile: $0.20

Adjust based on:

• Truck age (older = +$300-$500/month)
• Mileage (higher miles = +$200-$400/month)
• Your mechanical skills (DIY = -$200-$400/month)

Maintenance Records: Why They Matter

Proper maintenance records:

Help with resale:

• Documented PMs increase truck value 10-15%
• Buyers pay more for proven maintenance

Help with audits:

• DOT wants maintenance records
• Prove you're compliant

Help with diagnosis:

• "When did we last replace the X sensor?"
• Patterns emerge (helps predict failures)

Help with taxes:

• Deduct every penny spent
• Audit protection

What to keep:

• Every receipt (paper or digital)
• Oil analysis reports
• Parts invoices
• Labor invoices
• Inspection reports

The Bottom Line on Maintenance Costs

Here's what to actually expect:

First year (new truck):

• Monthly: $800-$1,200
• Annual: $10,000-$15,000
• Mostly predictable

Years 2-5 (under warranty):

• Monthly: $1,000-$1,500
• Annual: $12,000-$18,000
• Some surprises, but manageable

Years 6-10 (out of warranty):

• Monthly: $1,500-$2,500
• Annual: $18,000-$30,000
• More unpredictability

Years 10+ (high mileage):

• Monthly: $2,000-$3,500
• Annual: $24,000-$42,000
• Budget for major overhaul

The real question isn't "how much" but "did you budget for it?"

Most owner operators fail because they:

1. Don't set aside maintenance reserves
2. Spend the maintenance fund on other things
3. Get hit with a $10,000 repair and can't cover it

Don't be that owner operator.

Set aside the money EVERY month. Even when things are going well. Especially when things are going well.

Because the truck doesn't care about your cash flow. It will break when it breaks.

---

How FF Dispatch Helps Owner Operators Cover Maintenance Costs

Here's the brutal truth: You can't avoid maintenance costs. But you CAN earn enough to cover them comfortably.

That's where most owner operators struggle. They're taking $2.20/mile loads and then panicking when a $3,000 repair bill hits.

The real problem: You're not earning enough per load to build proper reserves.

How We Help You Afford Maintenance

We negotiate better rates on every single load. Not just finding freight – actual rate negotiation with brokers.

Example: Broker posts $2.40/mile. We negotiate to $2.75/mile. That's $350 more on a 1,000-mile load.

That $350 per load difference IS your maintenance fund.

Run 3 loads per week:

• Our rates: +$1,050/week in extra earnings
• Standard rates: $0 extra
• Monthly difference: $4,200

That covers:

• Your PM ($600)
• Unexpected repair ($500)
• Tire fund ($400)
• Emergency fund contribution ($500)
• Plus $2,200 left for you

What We Do

Negotiate every load (not just book it)

• We push brokers for better rates
• We know what lanes should pay
• We don't take the first offer

Get you paid faster

• Follow up on every invoice
• Chase down detention pay
• Get accessorials you'd normally miss

Simple pricing

• 6% of gross revenue
• You pay us after you get paid
• No hidden fees
• Cancel anytime (no contracts)

Real Results

Our owner operators average $2.65/mile vs $2.30/mile booking their own freight.

That $0.35/mile difference on 120,000 miles/year = $42,000 more annual revenue.

That $42,000 covers your entire maintenance budget with room to spare.

"Before FF Dispatch, maintenance costs stressed me out. I was taking cheap loads and praying nothing broke. Now I'm averaging $2.70/mile and my maintenance fund has $8,000 in it. That $1,200 PM bill? Covered. The $2,800 DEF system repair? Stressful but manageable. I'm actually building reserves instead of scrambling every month." – FF Dispatch client

Ready to earn enough to actually afford maintenance?

Call/Text: (302) 608-0609 Email: gia@dispatchff.com Website: new.dispatchff.com

---

Sources

• TEC Equipment: Semi Truck Service Intervals
• TruckersReport: Preventative Maintenance Schedule
• Freightliner: Preventive Maintenance
• Kenworth Truck Maintenance - TEL
• FreightWaves: Labor and Parts Costs Driving Maintenance Bills Higher
• AAA: Average Mechanic Labor Rates by State 2026
• Schneider O/O: Semi-Truck Maintenance Costs
• International Used Truck Center: Average Maintenance Cost
• TruckersReport: Independent O/O Costs 2021
• TruckersReport: Monthly Maintenance Budget
• BFS Fleet Service: Truck Repair Costs Breakdown
• Mann's Wrecker: Most Expensive Semi Truck Repairs
• UTI: Preventative Diesel Truck Maintenance Checklist
• AltLINE: Semi-Truck Maintenance Checklist and Schedule