Five HGV Parts You Need to Know About Before They Fail

HGVs are built to last, enduring the punishing conditions of long distance travel that would quickly finish off a lighter vehicle. But this durability is not infallible. Wear is inevitable, and without a keen eye and attention to detail, you might find yourself facing an unreasonably high repair bill.

Thankfully, a preventative mindset can make all the difference. Knowing which components are most likely to fail, recognising the early warning signs, and following sensible maintenance schedules can save you time and money in the long run.

In this article, we’ll look at the 5 HGV parts you need to know about before they fail, and what you need to look out for. Keep reading to learn more…

Brake systems

Brake systems are the single most safety-critical item on any heavy vehicle.

Brake wear is largely frictional and thermal. The combination of mass and speed creates enormous thermal and mechanical loads during braking which, repeated day after day, progressively degrade pads, shoes, drums, rotors and the pneumatic components that actuate them.

Pads and shoes thin with use, rotors, and drums develop heat‑related stress and can warp or crack, and pneumatic chambers, slack adjusters and valves suffer from corrosion and mechanical fatigue.

How to spot a failing brake system

Drivers will notice increased stopping distances, a spongy or low pedal, vibration when braking, or a pulsing sensation through the cab. Each is a sign that inspection and replacement are due.

General guidance for heavy vehicles recommends brake pad replacement in the tens of thousands of miles range, depending on duty cycle, though severe duty or frequent trailer braking can accelerate wear.

Rotors and drums last longer, but are not immune. High-mileage or high-heat applications shorten their service life.

In order to address any issues before they become a problem, HGVs must have their brakes tested by a roller brake tester at least four times a year, including the annual MOT. Each test will ideally be conducted while the vehicle is laden, though if that is not possible, a risk assessment is required to be completed and documented to justify it.

What can you do to prevent it?

The simple fact is that the process of driving will inevitably wear down your brake system, but that doesn’t mean there aren’t things you can do to mitigate the impact.

The biggest factor is driving technique. Avoid aggressive, late braking where possible, and use engine braking on long descents.

Don’t forget the adage “buy cheap, buy twice”. Fit parts specified for heavy-duty use rather than economy after market options. They cost more, but pay back in reliability and reduced downtime.

Lastly, stay vigilant. Regular measurements of lining thickness and routine checks of slack adjusters and service chambers can help to prevent unwelcome surprises.

If you need to replace parts on your brake system, at Truckstop, we stock a wide range of brake system parts to get your truck back in top shape.

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Tyres

Tyres are literally the truck’s interface with the road, bearing the weight of the vehicle and its load, all while confronting the relentless barrage of weather and road debris.

This constant impact makes HGV tyres one of the most vulnerable parts of the vehicle. Failures arise from under-inflation, overloading, impact damage, uneven wear and age-related cracking.

Burst tyres can be time-consuming and costly to replace, and oftentimes come at the most inconvenient moments, so preventing the worst from occurring is the best outcome.

How to spot a damaged truck tyre

The visible condition of a tyre is the most immediate way to check the vehicle’s readiness to operate safely.

You should inspect tyres for bulges, cuts, embedded objects, and irregular tread wear patterns which can reveal alignment, suspension, or inflation problems.

Speaking of inflation, this can be another indicator of tyre wear. Regular checks of tyre pressure will highlight signs of over or under-inflation, both of which can lead to failure. Under-inflated tyres degrade more quickly, whereas over-inflated tyres wear in the middle faster.

The role of the tyre will impact its wear. Steering tyres and drive tyres typically wear out faster than tyres on a trailer, unless the trailer is carrying extremely heavy loads.

The type of journey can also impact the longevity of the tyre. Tyres subjected to long-distance motorway driving typically last longer than tyres on local delivery or urban environments, where stopping, starting, and turning are more frequent.

What can you do to prevent it?

One of the best ways to prevent tyre failure is to keep in mind the longevity of your tyres.

Single-use tyres typically get between 80,000 to 100,000 miles of use. However, many worn tyres can be regrooved or retreaded, and it’s not uncommon for a truck to get up to 400,000 miles out of a tyre with a good quality retread.

Tyres that are over 5 years old should be regularly inspected, and tyres over 10 years old should be replaced.

Pressure is important too. HGV tyre pressure will be specified by the tyre manufacturer, yet they often fall between 8 and 9 bar (116-130 PSI). Checking the pressure against the manufacturer’s specifications will keep it in better condition for longer.

At Truckstop, we stock a range of specialist tyre tools to ensure your tyres are ready for the road.

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Clutch systems

The clutch acts as the bridge between engine and gearbox and, on manual HGVs, is one of the components most exposed to load and misuse.

Heavy loads, frequent gear changes in urban settings and poor driving can all impact the clutch, and when it starts to fail it doesn't politely wait for a depot.

Clutch damage undermines drivability and can lead to further transmission damage, so preventing it before the worst occurs is a must-have.

How to spot a failing truck clutch

Early signs are often subtle.

A clutch that slips under load, delayed engagement when you release the pedal, a change in pedal free play, or a noticeable loss of acceleration despite full throttle are all indications of a clutch in need of repair.

Grinding when selecting gears or a clutch pedal that feels loose or sticky are further indicators that the friction surface or release mechanism is compromised.

What can you do to prevent it?

One of the first indicators of clutch wearing out quickly is a burning smell, or unusual grinding noises when shifting gears.

The biggest impactors to clutch wear come down to the way you drive, and how you use the clutch.

Avoid riding the clutch and minimise unnecessary slipping. Ease the pedal smoothly and use the gear you need rather than holding the vehicle on the bite. Rev matching while you downshift is another good way to ensure your engine speed matches the wheel speed.

When stopped, sit in neutral rather than keeping the clutch pressed down. When on an incline, remember to use the handbrake properly, and not rely on the clutch and foot brake.

But as with all parts on a truck, a clutch has a finite lifespan. General guidance recommends that a truck’s clutch should be replaced every 50,000 to 100,000 miles, though driving habits, vehicle type, and maintenance will vary this estimate.

When replacement is due, choose quality friction kits and have the release and bearing inspected at the same time to avoid repeat labour. At Truckstop, we stock quality clutch parts for all major manufacturers and vehicles, so when the time comes to change your clutch, you can do so with confidence.

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Suspension systems

The suspension system in a HGV is designed to absorb road shock, provide stability, and keep the wheels tracking true.

To do this, they are subjected to constant cyclic stress, corrosion, and impact damage, and when these parts degrade, the ride quality, braking stability and tyre life all suffer.

How to spot a damaged suspension system

There are a number of common signs that occur when suspension systems are faulting. Uneven tire wear, truck drifting, excessive vibrations, and nose-dipping during braking are all signs that it’s time to inspect your suspension system.

The first step is to perform a visual inspection. Look for cracked or broken springs, oil leaks around shock absorbers, damaged or torn bushings, or any rust or corrosion.

Additionally, you can perform a bounce test. Push down on the truck’s bumper or side rail. If the truck continues to bounce more than twice, it’s a clear sign that the shock absorbers are worn out.

Listen out for noise. Any creaks, clunks, or grinding can be a sign of loose or failing suspension parts.

Lastly, check of tire wear patterns. If there are patches of unusual wear, such as cupping, or excessive wear on one side, this can help identify misalignment caused by worn shocks or failing suspension bushings.

What can you do to prevent it?

Regular maintenance is key. Perform the visual inspections outlined above during routine maintenance checks to catch those potential issues before they become a major problem.

This involves looking for suspension linkages and ensuring bushings are adequately lubricated to prevent friction. Check air pressure and airbags for signs of leakage or wear.

Unsurprisingly, tyres have a big impact on suspension, so keeping them properly maintained will solve two problems at once. Proper tire pressure and regular alignments prevent undue stress on suspension components.

While in use, make sure to avoid overloading the truck, as exceeding the recommended load capacity can strain the suspension and lead to premature wear and failure.

Finally, the simplest part is scheduling maintenance. Don’t wait for a component to completely fail. When you schedule maintenance for your truck, you can replace worn parts before they cause further damage.

At Truckstop, we have a wide range of quality truck suspension parts for major models and makes, so you can shop with confidence.

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Steering systems

Steering systems are the link between the driver and vehicle. When steering systems fail, the consequence is rapid loss of control rather than merely inconvenience.

On HGVs the system comprises steering box and drag link, tie rods and ends, power‑assist pump and hoses, track rods, idler arms and associated bushes and seals. Each element must remain tight, lubricated and free of contamination for predictable handling.

How to spot damage to truck steering systems

With many parts at play, there are a number of ways to determine if the steering system is not working properly.

The first is to pay attention to how it feels. A vague, heavy or jumpy steering wheel, sudden changes in effort when road surface changes, or vibration through the wheel at speed indicate mechanical wear or imbalance.

Any lateral movement when the wheel is rocked while stationary (with wheels on the ground) can reveal end‑float in tie‑rod ends, drag links, or the steering box, which needs immediate attention.

Pay attention to sound. Any new clunks, knocks, or creaks on turning, or when going over bumps can point to worn joints or collapsed bushes.

Again, the tyres can help to identify issues with the steering system. Rapid or asymmetric wear on the front tyres is usually a good indicator of geometry drift from worn steering components.

What can you do to prevent it?

As with all other parts of the truck, due diligence is your best ally.

Before venturing out, perform some pre‑trip checks. These should include a simple steering play test and a visual inspection of boots, linkages, and hoses. Look for torn gaiters, grease loss or corrosion.

Lubrication is another key tool. Grease all serviceable joints to the manufacturer schedule; dry joints admit grit and fail quickly. In addition to this, you should check your truck’s steering fluid every 6,000 to 10,000 miles, or during routine oil changes.

When you locate issues in your steering system, it is vital that you replace them, rather than re‑using slightly damaged parts. At Truckstop, we stock a range of premium steering system components to get your truck back on the road and in top shape.

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Keep your truck on the road with Truckstop

HGV maintenance is a constant but manageable challenge. The parts that typically fail are not mysterious, and with a few preventative measures, you can keep them from becoming a disaster.

But when the time comes to replace parts on your HGV, you need Truckstop.

As national distributors for top brands including Bosch, Hella, Wabco, Yuasa, Durite and many others, we can help you to fix any number of issues with your HGV.

Contact our team today to see how we can help.