International Truck Preventive Maintenance Checklist

Comprehensive maintenance schedule for all service classes (A through D)

Maintenance Class Overview

International Trucks require systematic preventive maintenance at different intervals. Each maintenance class builds upon the previous one, with Class A being the most frequent and Class D being the most comprehensive.

Class A

Interval: Every 10,000 miles / Monthly

Focus: Basic inspections, fluid checks, and safety verification

Class B

Interval: Every 20,000 miles / Quarterly

Focus: Intermediate service with filter changes and adjustments

Class C

Interval: Every 40,000 miles / Semi-annually

Focus: Comprehensive inspection and component servicing

Class D

Interval: Every 80,000 miles / Annually

Focus: Major overhaul service with detailed component inspection

Note: Always refer to the specific International Truck model's service manual for exact maintenance intervals based on operating conditions, application, and model year.

Class A Maintenance (10,000 miles / Monthly)

Complete these inspection and service items at every Class A maintenance interval.

Engine Systems

  • Check engine oil level and condition
  • Inspect coolant level and condition
  • Check for fluid leaks (oil, coolant, fuel)
  • Inspect air filter indicator
  • Check belt condition and tension
  • Inspect hoses for cracks or leaks
  • Check DEF level and quality
  • Visually inspect exhaust system for leaks

Electrical System

  • Inspect battery connections for corrosion
  • Check battery charge level
  • Test all exterior lights for operation
  • Check dash indicator lights functionality
  • Verify horn operation
  • Test windshield wipers and washers
  • Check charging system voltage
  • Inspect visible wiring for damage

Brake System

  • Check air brake pressure build-up time
  • Test low air warning device
  • Drain air tanks of moisture
  • Visually inspect brake components
  • Check brake pedal operation
  • Test parking brake functionality
  • Verify ABS indicator light operation
  • Check brake fluid level (hydraulic systems)

Driveline and Chassis

  • Check transmission fluid level
  • Inspect differential fluid level
  • Visual inspection of driveshaft
  • Check steering fluid level
  • Test steering for excessive play
  • Inspect suspension components visually
  • Check frame for visible damage
  • Inspect fifth wheel connection (if applicable)

Cab and Body

  • Check operation of doors and locks
  • Inspect mirrors for adjustment and damage
  • Test heating and A/C operation
  • Check seat belts functionality
  • Verify all gauges work properly
  • Inspect windshield for cracks/chips
  • Check seat adjustments and mounting
  • Test interior lights

Tires and Wheels

  • Check tire pressure in all tires
  • Inspect tires for damage and wear
  • Verify adequate tread depth
  • Check wheel lug nuts for tightness
  • Inspect wheel condition
  • Look for signs of oil leaks at wheel ends
  • Check valve stems and caps
  • Inspect for signs of misalignment

Class B Maintenance (20,000 miles / Quarterly)

Complete all Class A items plus these additional inspection and service items.

Engine Systems

  • Replace engine oil and filter
  • Service fuel filter/water separator
  • Test coolant freeze protection and SCA level
  • Inspect radiator and cap
  • Check turbocharger mounting and connections
  • Inspect air induction system
  • Check engine mounts
  • Test cooling fan operation

Electrical System

  • Test battery capacity (load test)
  • Clean battery terminals and connections
  • Check alternator output under load
  • Inspect starter connections
  • Test all switches and controls
  • Check fuse panel and relays
  • Test backup alarm (if equipped)
  • Scan ECM for fault codes

Brake System

  • Measure brake pad/lining thickness
  • Adjust brake slack adjusters (if non-automatic)
  • Check brake chamber pushrod travel
  • Test air governor cut-in/cut-out pressure
  • Inspect brake hoses and tubing
  • Check air dryer operation
  • Lubricate brake components
  • Inspect brake drums/rotors for wear or cracking

Driveline and Chassis

  • Lubricate chassis grease points
  • Lubricate steering linkage
  • Lubricate U-joints
  • Check driveline angles
  • Inspect suspension bushings and shackles
  • Check spring pins and hangers
  • Inspect shock absorbers
  • Lubricate fifth wheel (if applicable)

Cab and Body

  • Replace windshield wiper blades
  • Check door hinges and lubricate
  • Test operation of all power accessories
  • Inspect HVAC system ducts and vents
  • Test operation of all gauges and warning systems
  • Check pedal operation and free play
  • Inspect cab mounts and isolators
  • Test operation of emergency equipment

Tires and Wheels

  • Torque wheel lug nuts to specification
  • Inspect wheel bearing condition
  • Check for proper tire matching on dual assemblies
  • Inspect for irregular wear patterns
  • Measure and record tread depths
  • Verify proper tire inflation system operation (if equipped)
  • Inspect hub oil seals
  • Check wheel bearing end play

Class C Maintenance (40,000 miles / Semi-annually)

Complete all Class A and B items plus these additional inspection and service items.

Engine Systems

  • Replace air filter element
  • Replace fuel filters (primary and secondary)
  • Inspect EGR system components
  • Clean crankcase breather
  • Inspect aftertreatment system
  • Test engine compression or perform electronic analysis
  • Check injector performance via electronic diagnostics
  • Perform cooling system pressure test

Transmission and Driveline

  • Check transmission for proper shifting
  • Obtain transmission fluid sample for analysis
  • Inspect transmission mounts
  • Torque driveline components
  • Check clutch adjustment (manual transmissions)
  • Inspect PTO operation (if equipped)
  • Obtain differential fluid sample for analysis
  • Inspect transfer case (if equipped)

Brake System

  • Service air dryer (replace desiccant)
  • Disassemble and inspect brake components
  • Check brake camshaft bushings
  • Inspect brake chambers
  • Pressure test air system for leaks
  • Inspect brake relay valves
  • Test anti-lock brake system
  • Inspect air compressor and governor

Steering and Suspension

  • Check wheel alignment
  • Replace power steering filter (if equipped)
  • Inspect king pins or ball joints for wear
  • Check steering gear box mounting
  • Inspect suspension air bags (if equipped)
  • Check torque rod bushings
  • Inspect axle alignment
  • Test air suspension height control valves

Electrical and HVAC

  • Clean/service HVAC evaporator
  • Replace cabin air filter
  • Test HVAC performance
  • Inspect electronic control modules
  • Test all sensors and actuators
  • Perform software updates if available
  • Inspect alternator output and connections
  • Test starting circuit voltage drop

Frame and Chassis

  • Detailed inspection of frame rails and crossmembers
  • Check body mounts and hardware
  • Inspect fifth wheel for wear
  • Check fifth wheel adjustment
  • Inspect fuel tank mounting
  • Check exhaust system mounts
  • Inspect all air and electrical lines
  • Check DEF tank and lines

Class D Maintenance (80,000 miles / Annually)

Complete all Class A, B, and C items plus these comprehensive service items.

Engine Major Service

  • Perform valve adjustment
  • Replace coolant
  • Inspect water pump
  • Replace all belts
  • Replace all hoses
  • Overhaul or replace turbocharger (as needed)
  • Detailed inspection of engine mounts
  • DPF cleaning or regeneration efficiency test

Transmission Major Service

  • Replace transmission fluid
  • Replace transmission filter
  • Adjust or replace clutch (if manual)
  • Calibrate transmission electronic controls
  • Inspect transmission cooler
  • Replace shift linkage bushings (if manual)
  • Inspect bell housing
  • Check transmission range sensor calibration

Differential and Axle Service

  • Replace differential fluid
  • Inspect differential gears and bearings
  • Check axle breather operation
  • Replace wheel bearings or repack
  • Replace wheel seals
  • Inspect axle shafts
  • Check gear backlash and pattern
  • Inspect hub assemblies

Brake System Overhaul

  • Replace brake linings/pads as needed
  • Machine or replace drums/rotors as needed
  • Rebuild or replace brake valves
  • Replace brake chambers (if approaching age limit)
  • Overhaul air dryer
  • Replace brake hoses
  • Service or replace slack adjusters
  • Test all retarder or engine brake systems

Steering System Overhaul

  • Replace power steering fluid
  • Service or replace steering gear
  • Replace tie rod ends if worn
  • Replace king pins or ball joints if worn
  • Service steering pump
  • Replace steering linkage bushings
  • Perform complete alignment
  • Check steering column and intermediate shaft

Suspension System Overhaul

  • Replace worn suspension bushings
  • Check spring condition and replace if needed
  • Replace worn shock absorbers
  • Inspect air suspension components
  • Rebuild height control valves
  • Replace suspension air bags if cracked or leaking
  • Inspect walking beam bushings and pins
  • Check suspension mounting components

Electrical System Overhaul

  • Replace batteries
  • Service or replace starter
  • Service or replace alternator
  • Clean and seal electrical connections
  • Check and update ECM programming
  • Replace worn switches and controls
  • Test and calibrate all sensors
  • Complete diagnostic check of all electronic systems

Fifth Wheel and Frame Service

  • Completely disassemble, clean and rebuild fifth wheel
  • Check frame for cracks and repair if needed
  • Replace fifth wheel bushings
  • Replace liner plate if worn
  • Lubricate all fifth wheel components
  • Test locking mechanism
  • Check slider mechanism (if equipped)
  • Inspect and torque all frame fasteners
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