Truck Maintenance and Repair Process
1.Initial Inspection & Diagnosis
- Intake & Documentation: Vehicle details are recorded (VIN, mileage, owner info) and a preliminary visual inspection is conducted.
- Fault Identification:
- Computer diagnostics using OBD-II scanners - Physical checks for leaks, wear, and damage
- Test drive (if operational) to assess performance issues
- Consultation with driver about symptoms
2.Disassembly Process
- Component isolation using protective measures
- Systematic disassembly of affected systems:
- Engine components
- Transmission system
- Brake assemblies
- Suspension parts
- Parts cleaning using:
- Solvent baths
- Ultrasonic cleaning
- Steam cleaning
3.Repair/Replacement Phase
- Component Evaluation**:
- Dimensional checks with micrometres
- Material integrity testing (cracks/warping)
- Wear pattern analysis
- Repair Techniques:
- Engine rebuilding (bearing replacement, cylinder honing)
- Transmission overhaul
- Hydraulic system repair
- Electrical system troubleshooting
- Replacement Protocol:
- OEM vs aftermarket parts selection
- Bearing and seal installation
- Torque-to-yield fastener replacement
4.Reassembly Procedure
- Clean room protocols for sensitive components
- Lubrication application:
- Assembly lubes
- Anti-seize compounds
- Gear-specific lubricants
- Precision alignment:
- Laser alignment for drivetrains
- Wheel end bearing preload adjustment
- Fastening systems:
- Torque wrench calibration
- Stretch bolt replacement
5.Post-Repair Verification
- System Testing:
- Dynamometer testing for powertrains
- ABS system cycling
- Emission control verification
- Quality Assurance:
- Pressure testing (cooling systems)
- Vibration analysis
- Thermal imaging for electrical systems
- Final Validation:
- Load testing (for suspension repairs)
- Extended road test with data logging
- Post-repair diagnostic scan
6.Pre-Delivery Preparation
- Fluid level standardization
- Tire pressure adjustment
- Software updates (ECU programming)
- Safety system verification (lights, horns, ABS)
- Final detailing and corrosion protection
7.Documentation & Client Briefing
- Repair summary documentation
- Warranty information processing
- Maintenance schedule updates
- Driver operational recommendations
8.Specialized Processes
- Frame straightening using laser measurement
- CAB (Cab and Body) separation techniques
- Aftertreatment system regeneration (DPF/SCR)
- Hybrid/Electric systems deactivation protocols
9.Safety Protocols
- Lockout/tagout procedures
- PPE requirements
- Environmental compliance (fluid containment)
- Lifting equipment safety checks
This comprehensive process ensures commercial vehicles meet original equipment specifications and comply with DOT regulations. Each phase incorporates quality control checkpoints to maintain repair integrity and operational safety.
