For many fleets, the question is no longer whether repair and maintenance costs are rising, but how to manage those costs without sacrificing reliability. Trucks are staying in service longer, replacement equipment remains a significant investment, and every unplanned day in the shop can affect revenue, schedules and customer commitments.

During a recent episode of Commercial Carrier Journal's 10-44, Tommy Slaymaker of The Pete Store explained why the right answer is not always simply to keep repairing an older asset. The better decision comes from understanding the truck's total cost of ownership, its remaining value and the operational risk that arrives as major components reach the end of their expected life.

Why Fleets are Holding onto Trucks Longer

The disruptions that followed COVID pushed many fleets out of their normal purchasing cycles. Equipment allocations limited access to new trucks, leaving operators with little choice but to retain existing assets longer than planned. Fleets have spent the years since trying to catch up while also navigating freight-market conditions and changing emissions requirements.

That extended ownership cycle can create a compounding cost problem. As warranties expire and mileage climbs, fleets often encounter more frequent repair events, higher costs per mile and longer periods of downtime. The truck may be paid for, but that does not necessarily make it inexpensive to operate.

Finding The Repair-Versus-Replace Threshold

Every fleet's breakeven point is different. Application, annual mileage, duty cycle, maintenance history and resale demand all influence when it makes sense to trade a truck rather than continue repairing it. Still, Tommy noted that larger repair costs often begin appearing around 450,000 to 600,000 miles, or approximately five to six years of service. Engine and transmission failures become more likely, and the overall cost per mile can rise quickly.

" The goal is to move an asset before major component failures, rising cost per mile and lost uptime erase the value of keeping it longer." -  Tommy Slaymaker, CCJ interview

A sound replacement strategy looks beyond the next repair invoice. Fleets should compare projected maintenance spending and downtime against financing costs, warranty coverage, expected residual value and the productivity of a newer asset. Trading before major component warranties expire may help preserve resale value while reducing exposure to costly failures.

Preventive Maintenance Remains the First Line of Defense

Whether a fleet is preparing to replace equipment or planning to retain it, a disciplined preventive maintenance program is essential. In hot weather, cooling-system performance becomes especially important because excess heat can contribute to aftertreatment problems. Tires, brakes, hoses, clamps and batteries also deserve close inspection.

Preparation should shift as colder weather approaches. Tommy recommends checking air-dryer systems and cartridges, HVAC systems and filters, batteries and block heaters before temperatures drop. Stocking anti-gel ahead of winter can also help fleets avoid preventable disruptions when cold weather arrives.

Stay Ahead of Aftertreatment Issues

Aftertreatment technology continues to evolve, but maintenance practices still matter. A single aftertreatment-related failure can be especially damaging for an owner-operator or small fleet because one sidelined truck may represent a large share of the business's earning capacity.

Tommy encourages operators to ask service teams direct questions: Should this system be serviced sooner for the truck's application? How often should a standalone regeneration be performed? When should filters be inspected or replaced? A maintenance interval that works for one fleet may not be appropriate for another, so service decisions should reflect real duty cycles and operating conditions.

The Hidden Cost of a Cheaper Fuel Filter

One of Tommy's strongest cautions involved fuel-system maintenance. Saving a few dollars on a non-OEM fuel filter can become expensive if the filter contributes to restricted fuel pressure, clogged injectors, fault codes or a derate. Many aftertreatment systems will not regenerate while a fuel fault is active, which can turn a small parts decision into roadside downtime.

The lesson is straightforward: follow the engine manufacturer's filter specifications. The right component may cost slightly more at the counter, but it can help protect a much larger investment in the fuel and aftertreatment systems.

Make the Decision with the Full Cost in View

Repairing an older truck can make sense when the asset remains reliable, maintenance costs are predictable and its application still fits the fleet's needs. Replacement becomes more compelling when repair frequency rises, warranties have expired, residual value is declining and downtime begins disrupting the operation.

The most effective fleets do not wait for a catastrophic failure to begin that analysis. They monitor cost per mile, repair frequency, downtime, mileage, warranty status and resale value throughout the ownership cycle. Combined with proactive seasonal maintenance and the correct replacement parts, that visibility helps fleets make a planned business decision instead of an emergency one.

Need help evaluating maintenance priorities or planning for your fleet's next equipment cycle? Contact your local The Pete Store team.