Free truck 100,000 km service checklist
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A step-by-step 100,000 km (major) service procedure for rigid trucks, prime movers and heavy vehicles. This service includes all 15,000 km minor service tasks plus comprehensive component replacements: coolant flush, transmission and differential oil changes, full brake reline, wheel bearing replacement, fan belts, valve clearance, injector inspection, chassis and steering inspection, and air system service. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.
Last updated: 2026-03-26 · MapTrack
Commercial Director
How to use: Complete the 15,000 km minor service first. Then fill vehicle details and odometer reading, work through each additional service action. Tick Done as each task is completed. Record fluid quantities and part numbers used. Set the next service due kilometres and sign off.
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See the first part of the service procedure below. Enter your email above to download the full truck 100,000 km service procedure (PDF-ready).
What is a truck 100,000 km service?
A 100,000 km service is a major service for rigid trucks, prime movers and heavy vehicles. It is performed every 100,000 kilometres (or per the manufacturer's service schedule) and is the most comprehensive scheduled service interval. The procedure includes all 15,000 km minor service tasks (oil, filter, grease, inspections) plus replacing fuel filters, air filters, coolant (full flush), transmission oil, differential oil, power steering fluid, brake linings, wheel bearings, fan belts, air dryer cartridge, and inspecting the turbocharger, valve clearance, fuel injectors, chassis rails, steering components, suspension and air system. It is a full-day workshop service performed by a qualified heavy vehicle mechanic.
Benefits of major truck servicing
- Prevent major failures: replacing transmission and differential oil, coolant and brake linings at the correct interval prevents catastrophic component failures that can cost tens of thousands of dollars.
- Extended vehicle life: comprehensive fluid changes and component inspection at 100,000 km keep the vehicle's drivetrain and chassis in serviceable condition for hundreds of thousands of additional kilometres.
- Safety compliance: full brake reline, wheel bearing replacement, steering inspection and chassis crack checks are critical for on-road safety and Chain of Responsibility compliance.
- Reduced total cost of ownership: investing in a thorough major service avoids the compounding repair costs that result from deferred maintenance.
- Documented history: a completed 100,000 km service record demonstrates professional fleet management and significantly increases the vehicle's resale value.
Benefits of digitising forms in MapTrack
When you move from paper or static PDFs to digital forms in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
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- Electronic signatures.
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- Build forms with AI (describe what you need and MapTrack suggests the form).
Book a demo to see digital service procedures and km-based scheduling in MapTrack.
Service actions included in the 100,000 km procedure
This service procedure covers 20 additional service actions (beyond the 15,000 km minor service) across 7 system areas:
- Engine (additional): replace fuel filters (primary and secondary), replace air filters (outer and inner), drain, flush and replace coolant, replace fan belts, inspect turbocharger, check and adjust valve clearance, inspect fuel injectors, full DPF service.
- Drivetrain (additional): drain and replace transmission oil and filter, drain and replace differential oil (all diffs), replace power steering fluid.
- Brakes (additional): full brake reline (reline drums or replace pads), inspect and measure brake drums/discs.
- Wheels and bearings: repack or replace wheel bearings all positions.
- Steering and suspension: full steering inspection (drag link, tie rods, pitman arm, steering box), inspect suspension bushes, shackles, U-bolts and spring packs.
- Chassis and structural: inspect chassis rails for cracks (visual and dye penetrant if needed), inspect 5th wheel and jaws (prime mover).
- Air system: service air dryer (replace desiccant cartridge), test air system (governor, safety valve, tank drain).
Fluid specifications
General fluid specifications for rigid trucks and prime movers. Capacities vary by engine size and drivetrain configuration.
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 or 10W-40 CI-4/CK-4 | 20 - 40 L |
| Coolant | 50/50 ethylene glycol | 30 - 50 L (full system) |
| Transmission oil | Allison TES 295 or 80W-90 manual | 15 - 30 L (system) |
| Diff oil | 80W-140 or 85W-140 GL-5 | 8 - 15 L per diff |
| Power steering | ATF | 3 - 5 L |
| AdBlue / DEF | ISO 22241 | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines. Always refer to the manufacturer's service manual for your specific make and model.
Parts and consumables
Have the following parts and consumables ready (in addition to all 15,000 km service parts):
- Fuel filters (primary + secondary) - 1 set
- Air filters (inner + outer) - 1 set
- Coolant (full system flush and refill) - 30-50 litres
- Transmission oil + filter - 15-30 litres
- Differential oil - 8-15 litres per diff
- Power steering fluid - 3-5 litres
- Brake linings / pads - 1 set
- Wheel bearing kits - as required
- Fan belts (accessory + drive) - 1 set
- Air dryer desiccant cartridge - 1
Look up part numbers in the manufacturer's parts manual for your specific make and model before ordering.
How to perform a truck 100,000 km service
- Complete the 15,000 km minor service first (engine oil and filter, grease, brake measurement, tyre checks, electrical testing).
- Record the vehicle details and current odometer reading at the top of the major service procedure form.
- Engine section: replace fuel filters (primary and secondary), replace air filters (outer and inner), drain, flush and replace coolant, replace fan belts, inspect turbocharger, check valve clearance, inspect injectors and complete full DPF service.
- Drivetrain section: drain and replace transmission oil and filter (auto) or gearbox oil (manual), drain and replace differential oil (all diffs), flush and replace power steering fluid.
- Brakes: perform full brake reline (reline drums or replace pads if below spec), inspect and measure brake drums/discs.
- Wheels: repack or replace wheel bearings all positions.
- Steering and suspension: full steering inspection (drag link, tie rods, pitman arm, steering box), inspect suspension bushes, shackles, U-bolts and spring packs.
- Chassis: inspect chassis rails for cracks, inspect 5th wheel and jaws (prime mover).
- Air system: service air dryer (replace desiccant cartridge), test governor, safety valve and tank drain.
- Start the engine and check for leaks, abnormal noises or warning lights. Record any defects in the notes section. Set the next service due kilometres and sign off.
In MapTrack, you can schedule services based on odometer readings, get automatic reminders, complete service procedures on mobile and link every record to the vehicle. Book a demo to see how.
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Back to download formTruck service interval hierarchy
Truck maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.
Engine oil and filter, grease driveline and chassis, fluid level checks, brake measurement, tyres, lights, DPF and AdBlue. Estimated 2-3 hours.
100,000 km - Major service (you are here)
All 15,000 km tasks plus coolant flush, transmission oil, differential oil, full brake reline, wheel bearings, fan belts, valve clearance, injectors, chassis inspection and air system service. Estimated 6-10 hours.
In MapTrack, you can configure service schedules by odometer readings and receive automatic alerts when each interval is due.
Frequently asked questions
- What is included in a truck 100,000 km service?
- A 100,000 km truck service is a major service that includes all 15,000 km minor service tasks plus replacing fuel filters (primary and secondary), replacing air filters (outer and inner), draining, flushing and replacing coolant (full system), draining and replacing transmission oil and filter, draining and replacing differential oil (all diffs), replacing power steering fluid, full brake reline (reline drums or replace pads if below spec), inspecting brake drums/discs, repacking or replacing wheel bearings, replacing fan belts, inspecting the turbocharger, checking and adjusting valve clearance, inspecting fuel injectors, inspecting chassis rails for cracks, full steering inspection, inspecting suspension components, full DPF service, inspecting the 5th wheel (prime mover), servicing the air dryer and testing the air system. It takes approximately 6 to 10 hours.
- What is the difference between a 15,000 km and 100,000 km truck service?
- A 15,000 km service is a minor service that covers engine oil and filter, basic fluid level checks, greasing, brake measurement, tyre checks and electrical testing. A 100,000 km service is a major service that includes all 15,000 km tasks plus comprehensive component replacements: coolant flush, transmission and differential oil changes, full brake reline, wheel bearing replacement, fan belts, valve clearance adjustment, injector inspection, chassis and steering inspection, and air system service. The 100,000 km service takes approximately 6-10 hours compared to 2-3 hours for the minor service.
- How much does a truck major service cost?
- A 100,000 km major truck service typically costs between $2,000 and $6,000 depending on the vehicle size, engine type and condition of components. Parts alone (filters, oils, coolant, brake linings, wheel bearings, belts) can cost $1,000-$3,000. Labour for 6-10 hours adds $600-$2,000. Skipping major services often leads to significantly more expensive breakdown repairs. Documenting service costs per vehicle helps fleet managers forecast maintenance budgets.
- Is the template free to use without MapTrack?
- Yes. Download and use the truck 100,000 km service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each vehicle with km-based scheduling, cost tracking and alerts, we would be happy to show you MapTrack.
Need digital service procedures scheduled by kilometres?
Register every truck in MapTrack. Set up 15,000 km and 100,000 km service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.
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