6 Common Diesel Truck Bodywork Issues (And How to Spot Them Early)
May 14, 2025
Why Bodywork Issues Deserve More Attention Than You Think
When it comes to diesel truck bodywork issues, they’re often seen as cosmetic or non-urgent—but that couldn’t be further from the truth. Body damage can compromise structural integrity, expose critical components, and even lead to compliance violations. Especially in places like Greer, SC, where humidity and road salt can be unforgiving, early detection is key to avoiding costly repairs or downtime.
Let’s walk through the most common problems affecting diesel truck bodies and how to spot them before they turn into major headaches.
1. Rust and Corrosion
Rust is more than just an eyesore. It’s a sign that metal is deteriorating—and if left unchecked, it can weaken frames, mounts, and even fuel tanks.
How to Spot It Early
● Inspect fender wells, undercarriages, and door sills where moisture tends to collect ● Look for bubbling paint, flaking, or orange discoloration
● Pay close attention after winter, especially if your truck’s seen salted roads
In South Carolina, the humidity can also accelerate corrosion, even without snow. Washing your truck regularly and applying anti-corrosion coatings can help mitigate this issue.
2. Cracked or Dented Panels
Dents might seem harmless, but they can hide structural damage or compromise aerodynamics, affecting fuel efficiency.
How to Spot It Early
● Run your hand over surfaces to feel for indentations you might not see ● Use a flashlight to check for shadow lines under inspection lighting ● Inspect post-loading and unloading—tight docks are notorious for causing sidewall dents
Even minor panel damage should be documented, as repeated flexing can lead to cracking over time.
3. Loose or Misaligned Body Panels
When body panels shift, it often means something else has moved—potentially due to frame flex or impact. Misaligned doors or fairings can also create drag and increase fuel costs.
How to Spot It Early
● Watch for gaps between cab and trailer fairings
● Doors that don’t latch smoothly or rub when closing are red flags
● Inspect mounting hardware for signs of rust or fatigue
Regularly check the tightness of bolts and mounts during scheduled service intervals to avoid panel separation on the highway.
4. Broken or Missing Lights and Reflectors
DOT regulations require all reflectors and lights to be functional and visible. Not only do missing or broken ones invite inspection fines, but they also reduce visibility—especially during long hauls at night.
How to Spot It Early
● During pre-trip inspections, test all brake, turn, and marker lights
● Walk around the truck with lights activated to check for dimming or outages ● Replace cracked light housings promptly—moisture inside is a sign of pending failure
At Gregory’s Trailer and Truck Service, we often see this overlooked until it results in a failed inspection or ticket.
5. Damaged Skirts and Fairings
Side skirts and fairings improve aerodynamics and fuel efficiency. But they’re low to the ground, making them vulnerable to damage from curbs, ice chunks, or road debris.
How to Spot It Early
● Look for visible cracks or missing fasteners alongside panels
● Listen for flapping sounds when driving at speed—this can indicate a loose component
● During refueling or parking checks, inspect skirts for damage from tight turns or loading docks
Fixing damaged fairings quickly keeps your truck aerodynamic and DOT-compliant.
6. Cracked Windshields and Window Seals
Cracks may start small, but they grow fast—especially when exposed to fluctuating temperatures. A cracked windshield weakens cab integrity and can be a roadside inspection failure.
How to Spot It Early
● Check corners of the windshield for stress fractures
● Inspect rubber seals for dryness or cracking
● Watch for water leaks during rain or washing—this signals a seal issue South Carolina’s hot sun and thunderstorms make glass and seal wear a regular concern.
Why Early Detection Saves Time and Money
Small bodywork issues often escalate into expensive repairs if ignored. For instance, untreated rust can spread to the frame. A misaligned fairing could lead to increased fuel costs. Regular inspections and preventive maintenance help you stay ahead of problems, ensuring both compliance and performance.
At Gregory’s Trailer and Truck Service, we believe that paying attention to bodywork is just as important as maintaining your engine. It’s part of what keeps your truck safe, legal, and running efficiently on the roads of Greer and beyond.
Learn More
Bodywork issues on diesel trucks are not just surface problems. They can lead to safety concerns, performance inefficiencies, and regulatory headaches if left unchecked. By knowing what to look for—whether it's rust, panel misalignment, or light failures—you can catch these issues early and avoid the cost of major repairs down the line.
For thorough bodywork inspections and repairs, Gregory’s Trailer and Truck Service in Greer, SC, is here to help keep your fleet in top form.