Critical failure of a car or truck’s internal systems—including its engine, brakes, or suspension—is the root cause of 44,000 crashes each year in the United States.
Preventing engine failure is vital for staying safe on the road.
It’s also cost-effective! Consider this: once an engine has died, the cost of replacing, say, a V8 starts at $4,500, at an absolute minimum.
Meanwhile, the typical diesel engine of a heavy-duty vehicle runs between $20,000-$40,000. Even an in-frame rebuild, with refurbished parts, costs between $7,800 - $17,000 for an HDV.
Yet, by comparison, the cost to prevent the most common causes of engine failure is pocket. Fixing a radiator leak typically costs under $500; replacing fuel injectors runs from $300-$900; and a regular oil change is 99% cheaper than even the lowest-end diesel engine.
Save money and stay safe with our expert guide to truck engine failure prevention.
5 Most-Common Truck Engine Problems, Explained
To prevent engine failure, understand its root causes. Then, learn how to heed warning signs.
What Causes HDV Engine Failure?
Engines typically fail due to overheating, over-aeration (too much air in the engine), or malfunctioning components in the vehicle’s internal systems. Generally, problems occur in the following five categories.
Bad Motor (Internal Engine Damage)
Internal engine damage and motor problems threaten engine function in a few ways. These include:
Abnormal detonation (pressure surge), the spontaneous, inappropriate combustion of fuel and air in the engine’s combustion chamber, post-ignition. It’s a dangerous, swift, uncontrolled pressure increase.
Underlying causes of abnormal detonation include:
Low octane fuel
Heavy engine load
Extreme compression
Improper lubrication, which increases friction and damages engine parts.
Underlying causes include:
Oil leaks
Poor quality or inappropriate oil choice
Delayed oil changes
Buildup of engine sludge and carbon deposits. It reduces different systems’ functionality and increases the risk of contamination and overheating.
Underlying causes include:
Irregular or infrequent cleaning
Delayed filter changes.
Broken, warped, or dysfunctional components, which can cause friction or heat damage to the engine.
Engine Overheat
Overheating is another common factor in engine failure. The most common underlying causes of overheating include:
Dirty or contaminated engine coolant
A leak in the radiator or coolant system
A blown gasket
Problem With Exhaust System, Electrical System, or Ignition System Components
The complex components of a truck's exhaust, electrical, and ignition systems are vital for its function. When a component breaks or loses functionality, it poses an engine failure risk. The most common types of component dysfunction implicated in engine failure include:
Catalytic converter failure
Oxygen sensor failure
Spark plug malfunction
Dysfunctional EGR valve
Faulty ignition switch
This can cause abnormal detonation due to incorrect ignition timing.
Dead battery
Notably, fluid leaks and carbon buildup can also damage these systems.
Over-Aeration (Too Much Air In Engine)
When there’s too much air in the engine, it will degrade and, eventually, fail. The most common underlying causes of over-aeration include:
MAF airflow sensor malfunction or detachment
Vacuum leaks, often due to seal/gasket dysfunction
Dysfunction or detachment of other sensors (coolant temperature, oxygen, etc.)
Transmission System & Fuel System Malfunction
Problems with the transmission system or fuel system are also significant sources of engine failure. The most common underlying issues causing problems in these systems include:
Fuel contamination
Fuel leaks
Low transmission fluid
Clogged fuel filters
Dysfunctional or damaged transmission or fuel system components, including:
Fuel injectors
Fuel pumps
Solenoids
Gears
Torque converters
How Do You Know If Your Engine Is Bad? (Warnings)
Preventing engine failure demands staying alert to the most pressing signs of a bad engine. Assess your truck systematically, looking for the following signs your engine is going out.
15 Urgent Signs Of Truck Engine Problems
Five of these signs are urgent, indicating imminent failure. The other ten are earlier warning symptoms. Heed them as soon as possible.
Top 5 Signs Of An Engine Trouble Emergency (Near Failure!)
These signs indicate engine failure is imminent. All must be addressed immediately.
Loss Of Power or Brake Control
The most urgent warning, requiring immediate action, is a loss of power of brake control. If the truck won’t turn on, is slowing, is tilting while moving, or if brake time lengthens, stop. Engine failure is imminent or has already occurred.
Overheating Engine
If you see the “overheating” indicator on the dashboard glow red, it’s urgent. The indicator may be the word “TEMP” or a thermometer icon.
Other signs the engine is overheating include smoke or steam from the motor (under the hood), the hood being hot to the touch, and the smell of burning or melting components.
Dashboard Warning Lights
Dashboard warning lights alert drivers to different, critical engine issues.
The “TEMP” light indicates the engine is dangerously overheating.
The oil pressure warning light is a red, glowing oil can, indicating a low oil / lubrication emergency.
The “check engine” light, when flashing, indicates an engine emergency.
Notably, the “check engine” light is an icon on the dashboard, clustered near other instruments. It often includes the words “check engine” or “service engine soon.” When the light is simply glowing orange or yellow, rather than flashing, the warning is important but not urgent.
Excessive Exhaust Smoke
Any smoke from the engine compartment is a sign of immediate danger.
Excessive smoke from the exhaust similarly indicates a highly urgent problem. Blue smoke means the engine is burning lubricant oil, while black or gray smoke is a sign of rapidly worsening fuel system problems.
High-Pitched, Raspy, or Metallic Sound (Engine Pinging)
A high-pitched, metallic, rattling sound is the key sign of abnormal detonation. It’s dangerous and demands immediate attention. The sound is very loud, and it gets louder and faster when the truck increases speed.
Early Symptoms and Warning Signs Of Leaks, Contamination, & Internal System Problems
These signs indicate ongoing internal damage to your truck’s engine or exhaust system. While they don’t indicate an emergency situation demanding instant attention, they should still be addressed swiftly.
Unusual Sounds, Vibrations, Or Odors
Pay attention to rattling, tapping, or grinding sounds. These indicate a serious issue with valves or bearings. A high-pitched whine can indicate a fuel pump problem, while hissing and sizzling sounds indicate a leak.
The scents and odors that are most often symptoms of engine trouble include a sweet smell (indicating a coolant leak), a sulfuric “rotten egg” smell (a sign of valve or catalytic converter issues), and burning rubber (a sign of burnt belts or melting components). The smell of bleach is another indication of a coolant leak.
Inefficient Fuel Use
Reduced fuel efficiency can be a sign of many different types of problems. If your truck is using more fuel than normal, run an inspection to determine if the engine is the source of the problem.
Rough Idle
Your truck’s engine should run smoothly when idling. If it’s shaking, bouncing, and can’t maintain a steady RPM speed, heed that warning sign.
Engine Stalling Or Misfiring
When the engine stalls or misfires, it’s often a sign of a damaged oxygen sensor. It can also be an important indication of other engine issues, so run a thorough diagnostic.
Excessive Exhaust Smoke (White or Black)
While blue and gray exhaust smoke indicates an emergency, excessive smoke of any color is a sign of a problem. Excessive white or black exhaust smoke is a symptom of ongoing engine damage.
Exhaust Backfiring
Exhaust backfire happens when unburnt fuel in the exhaust pipe combusts. This is a critical sign of fuel system issues, or a malfunctioning spark plug. It should be addressed before it leads to over-aeration or similar causes of engine failure.
Power Loss
When a truck can’t start, or it struggles to accelerate or maintain speed, that’s an important sign. Power loss is an engine damage symptom that can stem from exhaust blockages, fuel system problems, or sensor malfunction.
Failed Emissions Test
A failed emissions test needs to trigger a thorough assessment. Often, problems posing a risk of engine failure are the culprits.
Involuntary Or Erratic Speed Change
If you experience an involuntary or erratic change of speed while either driving or idling your truck, that’s an important sign. Sluggish acceleration, power surging, and stalling can indicate serious engine problems. Often, surging and stalling are caused by MAF sensor dysfunction, vacuum leaks, air filter clogs, or fuel injector issues—any of which can lead to critical engine failure.
Visible Fuel Puddles Or Fuel Line Damage
Leaks will absolutely kill your engine if left unaddressed. Look for signs of fuel, oil, and coolant leaks daily. Visible damage, puddles, and dead plants beneath the truck are notable symptoms.
How To Safely Address Engine Failure Symptoms & Warning Signs
Drivers can address engine symptoms in four steps. It’s also wise to seek guidance from a certified automotive service technician, as they can perform more thorough evaluations.
Diagnostics
Diagnosing engine failure starts with observing visible signs (listed above).
To narrow in on the precise cause, conduct a thorough inspection for leaks and system component damage. A diagnostic scanning tool can likewise offer more in-depth insights into the problem's source.
Clean & Maintain Systems
Keep your truck’s systems at peak functionality by sticking to a regular cleaning and maintenance schedule. This includes periodically changing filters, oil, and transmission fluid.
Seek Professional Truck Service
It’s important to receive basic truck service seasonally. It’s also wise to schedule comprehensive services for your truck each year, including DOT inspections and repairs.
Repair or Replace Dysfunctional Parts
When inspections or diagnoses reveal a broken or malfunctioning part, timely repair is key.
Experts like our certified technicians can recommend the appropriate OEM or aftermarket replacement part for your engine. This lets us repair or replace the component before it causes any more damage to your engine.
At Point Spring & Driveshaft Co., we can even handle tricky repairs and unusual parts with our onsite machine shop. No matter the source of the problem, our technicians can fabricate custom components, repair tools, and precise parts for same-day replacement installation.
Truck Engine Failure Prevention Checklist
Paying attention to signs of potential engine failure is key. Likewise, preventative practices go a long way to maintaining engine health. Use this checklist to keep your truck’s engine in tip-top shape.
Check the engine as soon as the dashboard warning light turns on.
Inspect your truck’s systems for leaks, contamination, and damage before every trip.
Use the fuel and lubricant oil recommended by your vehicle’s manufacturer.
Change your truck’s oil every 5,000-7,500 miles.
Flush the coolant system every 30,000 miles.
Change your truck’s engine’s air filters every 15,000 - 30,000 miles.
Use fuel-system-additive cleaners to slow the rate of carbon buildup on your engine.
Manually decarbonize (de-grease and remove carbon deposits from) your truck’s systems with solvents and scrub brushing, or via media blasting, every 20,000 - 40,000 miles.
Specifically target:
The EGR valve
Intake and exhaust valves
EGR cooler
Intake tract
Fuel injectors
Decarbonize more frequently (every 16,000 miles or so) if you hear knocking, or if you observe similar signs of engine damage.
Perform a complete inspection, meeting DOT standards, once every year.
Keep Your Truck’s Engine Running Well With Point Spring & Driveshaft Co.
Engine failure prevention is a mandatory task when it comes to trucking safely. Whether your engine needs routine maintenance, or you're seeing signs of damage, it's wise to work with the experts.
The certified technicians here at Point Spring & Driveshaft Co. have decades of combined experience. We work with drivers directly to solve the problem right, getting you back out on the road fast.
To take advantage of our maintenance, diagnostic, repair, or fabrication services, call (412) 264-6714. Or, fill out the form below, and one of our auto professionals will reach out to you.