Free truck / heavy vehicle 100,000 km service procedure
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Free truck 100,000 km major service checklist (PDF-ready). Coolant flush, transmission, diff oil, brake reline and wheel bearings. Download free.
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What is a truck / heavy vehicle 100,000 km service procedure?
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.
For fleet operators, the 100,000 km service is both the most expensive and the most valuable scheduled maintenance event. It is the point at which all drivetrain fluids are replaced, brakes are fully relined, wheel bearings are repacked and critical structural inspections are performed. Skipping or deferring this service significantly increases the risk of catastrophic component failure, roadside breakdowns and Chain of Responsibility non-compliance. The investment in a thorough major service is consistently repaid through extended vehicle life, reduced emergency repair costs and maintained resale value.
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Benefits of using this truck / heavy vehicle 100,000 km service procedure
- 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.
- Regulatory compliance: a documented 100,000 km major service demonstrates compliance with the NHVR National Heavy Vehicle Inspection Manual and Chain of Responsibility obligations.
- Reduced emergency repairs: replacing all drivetrain fluids, brake linings and wheel bearings at the correct interval prevents the cascading failures that lead to expensive roadside breakdowns.
Benefits of digitising forms in MapTrack
When you digitise truck service procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a truck / heavy vehicle 100,000 km service procedure
This truck / heavy vehicle 100,000 km service procedure covers 7 key 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).
How to use this truck / heavy vehicle 100,000 km service procedure
- Complete the 15,000 km minor service first (engine oil and filter, grease, brake measurement, tyre checks, electrical testing).: Perform the full 15,000 km minor service checklist before starting major service tasks. This ensures baseline items such as engine oil, grease points and brake measurements are current before the deeper work begins.
- Record the vehicle details and current odometer reading at the top of the major service procedure form.: Capture the registration, make, model, VIN, engine serial, fleet number and exact odometer reading. Cross-reference the odometer against the fleet schedule to confirm the correct 100,000 km interval has been reached.
- 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.: Replace both primary and secondary fuel filters. Replace inner and outer air filter elements. Drain the cooling system completely, flush with clean water and refill with the correct concentration of coolant. Replace all drive belts. Inspect the turbo for shaft play, oil leaks and housing cracks. Check valve clearance with feeler gauges and adjust to specification. Inspect injectors for leaks. Perform a forced DPF regeneration or replace the DPF element if ash loading is at the service limit.
- 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.: Drain the transmission oil at operating temperature. Replace the internal filter (auto) or clean the magnetic drain plug (manual). Fill with the manufacturer-specified oil. Drain and refill all differentials including inter-axle diffs on tandem drive vehicles. Flush the power steering system and refill with clean fluid.
- Brakes: perform full brake reline (reline drums or replace pads if below spec), inspect and measure brake drums/discs.: Remove drums or callipers and measure lining thickness at all wheel positions. Reline any position that is at or approaching the minimum specification. Measure drum diameter or disc thickness and replace if worn beyond the service limit. Adjust automatic slack adjusters and verify correct operation.
- Wheels: repack or replace wheel bearings all positions.: Remove hubs, clean old grease from bearings and races. Inspect rollers and races for pitting, spalling or heat discolouration. Repack with fresh EP2 lithium complex grease or replace bearings if worn. Adjust bearing preload to the manufacturer specification.
- Steering and suspension: full steering inspection (drag link, tie rods, pitman arm, steering box), inspect suspension bushes, shackles, U-bolts and spring packs.: With the front wheels off the ground, check for play in the drag link, tie rod ends and pitman arm. Inspect the steering box for leaks and mounting bolt condition. Check each spring pack for cracked or broken leaves. Verify U-bolt torque, shackle pin wear and bush condition.
- Chassis: inspect chassis rails for cracks, inspect 5th wheel and jaws (prime mover).: Perform a visual inspection of both chassis rails from front to rear, paying particular attention to areas around suspension mounts, crossmembers and mounting brackets. Use dye penetrant testing on any suspect areas. For prime movers, inspect the 5th wheel top plate for wear, check jaw engagement and locking mechanism and grease the turntable.
- Air system: service air dryer (replace desiccant cartridge), test governor, safety valve and tank drain.: Replace the air dryer desiccant cartridge. Test the governor cut-in and cut-out pressures against the manufacturer specification. Pop-test the safety valve. Drain all air tanks and check for oil or water contamination. Inspect all air lines and fittings for leaks using soapy water.
- 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.: Run the engine to operating temperature and check for coolant, oil, fuel and air leaks. Verify all warning lights clear. Build air pressure to the governor cut-out and confirm the air system holds pressure. Record all findings and measurements. Set the next 15,000 km and 100,000 km service due readings and sign off.
In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.
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Back to download formHow often should you complete this service procedure?
A 100,000 km major service should be performed every 100,000 kilometres or per the manufacturer service schedule. For a line-haul prime mover travelling 150,000 to 200,000 km per year, this falls approximately every 6 to 8 months. For a rigid truck operating locally at 60,000 to 80,000 km per year, the major service falls approximately every 12 to 18 months.
Between major services, the 15,000 km minor service covers oil, filters, grease and basic inspections at regular intervals. Daily pre-start checks must be performed by the driver before each shift. Vehicles operating in severe conditions such as dusty haul roads, extreme temperatures or constant heavy loading may require shortened intervals. Always follow the manufacturer service schedule and your fleet maintenance policy.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- NHVR National Heavy Vehicle Inspection Manual (maintenance and inspection standards for heavy vehicles under the HVNL)
- AS 3706 - Road Vehicles, Requirements for Roadworthiness (inspection and compliance criteria for registered heavy vehicles)
- ADR - Australian Design Rules (design and safety standards for heavy vehicle components including brakes, steering and chassis)
- WHS Regulations 2011, Chapter 5 - Plant and Structures (PCBU duty to maintain mobile plant including fleet vehicles)
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