As 2025 unfolds, fleet maintenance patterns reveal a remarkable increase in brake-related repairs and a shift towards prolonged use of older trucks, driven by economic factors and recent recall impacts, according to Decisiv’s latest data.

The landscape of truck maintenance activity continues to trend upward as we move into 2025, driven by a combination of economic and operational factors. According to Decisiv’s exclusive data for the first quarter of 2025—shared with Fleet Equipment—service volume increased by about 10.3% compared to the previous quarter and rose approximately 6.8% year-over-year. This growth reflects ongoing uncertainties related to tariffs and shifts in freight volumes, which have resulted in more tonnage on the roads. Additionally, many fleets are choosing to delay investing in new trucks, thereby maintaining older vehicles longer. This practice results in increased mileage on aging assets, subsequently driving higher shop demand for routine and preventive maintenance.

Nick Pittinger, vice president of data services at Decisiv, remarked, “It will be interesting to see how various service activity factors influence whether service activity begins to decline due to lower freight volumes or continues to rise as fleets delay vehicle purchases and keep older trucks in service longer.”

A significant trend in this period is the dramatic rise in brake-related service activity. The VMRS 013 brakes category experienced a 93.6% increase year-over-year, largely attributable to a major ABS recall that extended into Q1 2025. Even when excluding recall work, brake services saw substantial growth—approximately 12% quarter-over-quarter and 8% year-over-year. This indicates that brakes have become a major driver of service activity and costs, highlighting their importance as a key maintenance focus for fleets in 2025.

In terms of service volume dominance, powertrain components continue to lead the way. For the fourth consecutive quarter, power plants accounted for 19.3% of all service operations. Exhaust systems remained prominent at 10.6%, while brakes occupied the second largest segment at 14%. Other areas showing notable growth included power take-off (PTO) systems, which increased by 13.4%, general accessories at 11.7%, and lighting systems at 10.2%. These figures collectively suggest that fleets are experiencing greater wear and use across several critical vehicle systems, not just braking components.

Conversely, some service categories have experienced declines. Notably, tire/tube/liner/valve work, manual transmissions, and clutches have posted decreases in activity during Q1. Clutches, in particular, have shown consecutive quarterly declines. Even exhaust systems, despite their overall high service share, have seen a slight decrease, possibly indicating improved durability or shifted maintenance schedules. Additionally, automated manual transmissions (AMTs), which had been steadily increasing in service activity, appear to have plateaued, suggesting that fleets may be stabilizing their repair patterns for this technology.

Supporting these insights is Decisiv’s updated VMRS code key 31 AI encoding model, which has significantly improved the accuracy and scope of service data classification. According to Pittinger, “With the new model, we've been able to encode a larger proportion of operations across several VMRS systems, such as lighting, brakes, and tires.” This refinement enables more precise trend tracking across 25 VMRS categories, providing fleets and dealers with sharper visibility into where their service dollars are being spent and how costs are evolving.

Looking ahead, regulatory changes related to emission standards and engine aftertreatment systems are anticipated to influence service needs. Pittinger noted that monitoring how fleets adapt to these upcoming legislation requirements will be particularly important, especially as they manage older equipment amid evolving compliance mandates.

Overall, the maintenance scene in 2025 is characterized by increased vehicle utilization, heightened brake service activity driven by recent recalls, and shifting trends in various vehicle systems. For fleet operators and service providers alike, leveraging detailed data and proactive maintenance strategies will be essential to manage rising service demands and costs effectively.

Source: Noah Wire Services