The First 15 Minutes: Safety First
1
Get Off the Road
Pull as far right as possible — the shoulder, an exit ramp, a rest area, a parking lot. Anywhere off the travel lanes. If you can’t move, turn on hazards immediately.
2
Set Up Triangles
FMCSA requires reflective triangles within 10 minutes of stopping. Place them at 10 feet, 100 feet, and 200 feet behind your truck. On a curve or hill, place one at least 500 feet back.
3
Assess the Situation
Can you diagnose the problem? Flat tire, overheating, electrical, air brake leak? What you know helps the repair service bring the right parts.
4
Call for Help
Roadside assistance, your dispatcher, or a mobile mechanic. Have your location ready: highway number, mile marker, direction of travel, nearest exit.
5
Secure the Truck and Cargo
Set parking brake, chock wheels if on a grade. If you have a load, it’s not going anywhere — but keep the trailer locked. Stay with the truck if safe.
6
Document Everything
Take photos of the breakdown, your location, the problem, and any damage. Note the time. This documentation matters for insurance claims and HOS records.
Night or limited visibility: Stay inside the cab with seatbelt on until help arrives. More truckers are killed on the roadside than in driving accidents. If you must exit, wear your safety vest and stay on the non-traffic side of the truck.
Who to Call (In Order)
911 — If There’s Danger
Fire, spilled fluids, hazmat, injury, or if you’re blocking traffic and can’t move. Always call first if anyone is in immediate danger.
Roadside Assistance
Your roadside assistance provider (if you have one). They dispatch repair trucks and manage the logistics. Save the number in your phone NOW — before you need it.
Dispatcher / Broker
Let them know you’re down. They need to manage the load: reschedule delivery, potentially arrange a tow to a nearby terminal, or dispatch a replacement truck.
Insurance Agent
If towing or major repair is needed, check your physical damage coverage. Many policies include towing/labor — but you need to know your deductible and any preferred shop requirements.
Roadside Assistance Options
| Provider | Cost | Coverage | Best For |
|---|---|---|---|
| National Truck Protection (NTP) | $200-$500/yr | Towing, tire, lockout, fuel delivery, mobile mechanic | O/Os wanting comprehensive coverage |
| OOIDA Roadside Assistance | $149-$279/yr (with membership) | Towing, tire, electrical, mechanical first aid | OOIDA members |
| FleetNet America | Per-call ($150-$500+ per event) | National network, mobile mechanics, towing | Fleets with multiple trucks |
| TA Truck Service | Per-call + membership options | 285+ service locations, mobile service | Drivers on TA/Petro routes |
| Physical Damage Insurance | Included in premium | Towing to nearest shop (check limits: $2K-$5K typical) | All insured trucks |
The $200/year question: Without roadside assistance, a single tow can cost $300-$1,000+ (heavy tow trucks charge $5-$15/mile). One breakdown pays for 1-3 years of coverage. This is not a place to save money.
Most Common Breakdowns and Typical Costs
Tire Blowout / Flat
$250–$600
Roadside tire service: $150-$300 labor + $200-$400 tire
Prevention: Check tire pressure weekly, inspect for damage at every stop, replace at 4/32 tread depth
Overheating / Coolant
$200–$3,000+
Simple: Low coolant, failed thermostat ($200-$500). Serious: Water pump, radiator, head gasket ($1,000-$3,000+)
Prevention: Check coolant level daily, inspect hoses and belts at every service
Electrical / Battery / Alternator
$150–$1,200
Jump start: $100-$200. Battery: $200-$400. Alternator: $500-$1,200
Prevention: Test batteries every 6 months, check connections for corrosion
Air Brake Issues
$300–$2,500
Air leak: $200-$500 to find and fix. Brake chamber: $300-$800. Compressor: $1,000-$2,500
Prevention: Daily air pressure check, listen for leaks, regular brake adjustments
Fuel System
$200–$4,000+
Fuel filter: $100-$250. Fuel pump: $500-$1,500. Injectors: $2,000-$4,000
Prevention: Change fuel filters on schedule, use quality fuel, keep tank above 1/4
DEF / Emissions
$500–$5,000+
DEF quality error: $200-$500 (system reset). DPF regen failure: $500-$2,000. SCR system: $2,000-$5,000+
Prevention: Use quality DEF, don’t ignore warning lights, keep up with regens
HOS Rules During a Breakdown
You CAN Use Adverse Conditions
A breakdown is an “adverse condition” under 49 CFR 395.1(b)(1). You may extend your driving window by up to 2 hours to reach the nearest safe location for repair. This applies to the 11-hour driving limit and 14-hour window.
Breakdown Time = On-Duty Not Driving
While waiting for repair, you’re on-duty not driving. This counts against your 14-hour window and 60/70-hour weekly limit. Log it accurately on your ELD.
If You Can’t Drive Within HOS
If the repair takes hours and you’re out of driving time, you’ll need a 10-hour off-duty period before driving again. Plan for this — it may mean sleeping at the repair shop or nearby.
ELD annotation: Add a note in your ELD explaining the breakdown: “Mechanical breakdown at mile marker 142 on I-80 westbound. Waiting for mobile tire service.” This protects you if DOT reviews your logs.
Emergency Kit: What to Keep in Your Truck
Required by Law
- 3 reflective triangles (FMCSA)
- Fire extinguisher (5 lb ABC rated)
- Spare fuses
Essential
- Flashlight + extra batteries
- Safety vest (high-vis, Class 2+)
- Basic tool kit (wrenches, pliers, screwdrivers)
- Jumper cables (heavy-gauge)
- Tire pressure gauge
- Duct tape, zip ties, electrical tape
- Coolant (1 gallon)
- Extra DEF (2.5 gallon)
Survival / Comfort
- Water (1 gallon minimum)
- Non-perishable food (protein bars, nuts)
- Blanket / sleeping bag
- Phone charger (12V + portable battery)
- Rain gear
- Work gloves
- First aid kit
- Cash ($100-$200 for emergencies)
The Insurance Connection
Physical damage insurance often includes towing. Most policies cover towing to the nearest repair facility — typically $2,000-$5,000 per occurrence. Check your policy for the limit and whether you need to use a preferred tow company. Using an out-of-network tow shop may mean paying the difference out of pocket.
Breakdown damage to cargo is a claim. If your reefer unit fails and spoils a load, that’s a cargo claim. If you’re broke down on the side of the road and someone hits your truck, that’s a collision or comprehensive claim. Document the timeline — when the breakdown started, when you called, how long until repair.
Downtime coverage (loss of income) may be available. Some policies offer rental reimbursement or downtime coverage that pays you a daily amount while your truck is being repaired. It’s usually $100-$300/day for up to 30 days. Ask your agent — the coverage costs very little but protects you from the biggest breakdown expense: lost revenue.
Does your policy include towing and downtime coverage? Do you know your limits?
Frequently Asked Questions
How long can I legally stay broken down on the shoulder?
There’s no strict federal time limit, but most states will tow you after 24-48 hours if you’re on a highway shoulder. Interstate shoulders are not parking spots — they’re for emergencies only. If the repair will take more than a few hours, arrange a tow to a repair facility. Some states will ticket you for extended shoulder parking even with triangles deployed.
Should I try to fix it myself to save money?
Only if it’s something simple and safe: adding coolant, replacing a fuse, inflating a tire. Do NOT attempt anything involving going under the truck on a highway shoulder, working on air brake systems roadside, or anything you haven’t done before. The safety risk isn’t worth the savings. A mobile mechanic costs $150-$300/hour — your life is worth more.
What if my breakdown makes me late for delivery?
Contact your broker/dispatcher immediately with your ETA. Most contracts allow for “force majeure” or mechanical breakdown. Document everything: photos of the breakdown, repair receipts, ELD records. If the receiver charges detention or refuses the load, your documentation protects you from paying those costs. Keep all repair receipts for potential reimbursement claims.
Does roadside assistance cover my trailer too?
It depends on the plan. Some roadside assistance programs cover the power unit only. Others cover the truck + one trailer. If you pull a reefer with its own engine, that may be a separate service call. Read the fine print before you need it. Trailer tire service is often the most-used benefit — make sure it’s included.