As mobile diesel technicians serving the I-35 corridor between Temple and Hillsboro, we see the same breakdown patterns over and over again. While some mechanical failures are unavoidable, many of the service calls we respond to could have been prevented with proper maintenance and awareness.
After analyzing thousands of roadside repairs, here are the top 5 causes of diesel breakdowns we encounter on I-35—and what you can do to avoid them.
1. Cooling System Failures (35% of calls)
The Problem: Texas heat is brutal on diesel engines, especially during summer months when temperatures regularly exceed 100°F. Add in the stop-and-go traffic through Austin and San Antonio approaches, and cooling systems get pushed to their limits.
Common Issues We See:
- Radiator leaks from road debris damage
- Failed water pumps from overheating
- Burst hoses from age and heat cycling
- Thermostat failures causing overheating
- Low coolant levels from slow leaks
Prevention Tips:
- Check coolant levels daily during pre-trip inspections
- Replace radiator hoses every 4-5 years or when they show cracking
- Clean radiator fins monthly to remove bugs and debris
- Monitor temperature gauge constantly, especially in heavy traffic
- Address small leaks immediately before they become major failures
“We’ve seen trucks overheat just sitting in Austin traffic on a 105°F day. Your cooling system is working overtime in Texas—don’t push it beyond its limits.” - Senior Technician, I-35 Diesel Repair
2. DPF and Aftertreatment Problems (25% of calls)
The Problem: Modern diesel engines require sophisticated emission control systems, but the constant traffic slowdowns on I-35 don’t allow these systems to complete their regeneration cycles properly.
What Happens:
- DPF (Diesel Particulate Filter) clogs from incomplete regens
- DEF (Diesel Exhaust Fluid) system failures
- SCR catalyst contamination
- Engine derating or shutdown to protect emissions equipment
Prevention Strategy:
- Perform manual regens when warning lights appear
- Use high-quality DEF and keep tanks topped off
- Take highway drives at operating temperature to complete auto-regens
- Don’t ignore emissions warning lights—they only get worse
- Schedule regular DPF cleaning during maintenance intervals
3. Tire-Related Breakdowns (20% of calls)
The Problem: The I-35 corridor sees heavy freight traffic, construction zones, and road surfaces that are hard on tires. Texas summer heat makes tire failures even more likely.
Most Common Tire Issues:
- Blowouts from overloading or underinflation
- Road hazard damage from construction debris
- Heat-related failures on 100°F+ days
- Worn tires from improper alignment
Keep Rolling with These Tips:
- Check tire pressure when tires are cold (before driving)
- Inspect tires during every pre-trip for cuts, bulges, or embedded objects
- Maintain proper load distribution
- Replace tires before they reach minimum tread depth
- Keep quality tire repair kit and know how to use it
4. Electrical and Battery Problems (12% of calls)
The Problem: Modern trucks have complex electrical systems with hundreds of sensors and control modules. Texas heat accelerates battery failure and can cause wiring issues.
Electrical Issues We Handle:
- Dead batteries from heat or age
- Alternator failures from overwork
- Loose or corroded connections
- Sensor failures triggering check engine lights
- Wiring damage from road vibration
Stay Powered Up:
- Test battery and charging system every 6 months
- Clean battery terminals regularly
- Check belt tension on alternator
- Address warning lights promptly
- Carry quality jumper cables or battery pack
5. Fuel System Complications (8% of calls)
The Problem: Fuel contamination, filter clogs, and fuel pump failures can leave you stranded, especially when running low-quality diesel or missing fuel filter changes.
Fuel System Failures Include:
- Clogged fuel filters from contaminated fuel
- Failed fuel pumps
- Water in fuel causing rough running
- Dirty fuel tanks affecting entire system
Fuel System Best Practices:
- Change fuel filters on schedule, not when they’re clogged
- Use quality fuel stations with high turnover
- Add fuel conditioner in winter months
- Keep spare fuel filters for emergencies
- Don’t let fuel tanks get below 1/4 tank
The I-35 Factor: Why Location Matters
The Interstate 35 corridor through Central Texas creates unique challenges for diesel engines:
- Heavy Traffic: Stop-and-go conditions prevent proper DPF regeneration
- Extreme Heat: Texas summers push cooling systems beyond design limits
- Construction Zones: Road debris causes tire damage and radiator punctures
- High Freight Volume: Overloaded trucks stress mechanical components
- Remote Stretches: Limited service options between major cities
When Prevention Isn’t Enough
Even with perfect maintenance, breakdowns still happen. When they do, having a reliable mobile repair service can save you hours of downtime and hundreds of dollars in towing fees.
If you’re broken down on I-35 right now:
- Move to the safest location possible
- Set up reflective triangles if you have them
- Call our emergency line immediately: (972) 975-7026
- Stay with your truck when safe to do so
Our mobile repair units are strategically positioned to reach any location between Temple and Hillsboro within 45 minutes on average. We carry the diagnostic equipment and common repair parts to get most trucks back on the road without requiring expensive towing to a shop.
Your Breakdown Prevention Checklist
Print this checklist and keep it in your cab:
Daily Pre-Trip:
- Check coolant level and look for leaks
- Inspect all tires for pressure and damage
- Verify DEF levels and top off if needed
- Test all lights and electrical systems
- Check oil level and quality
Weekly Maintenance:
- Clean radiator of bugs and debris
- Check battery terminals for corrosion
- Inspect belts and hoses for wear
- Review maintenance schedule for upcoming services
Warning Signs to Never Ignore:
- Temperature gauge running hot
- Any emissions system warning lights
- Unusual engine noises or vibrations
- Changes in oil pressure
- Electrical system malfunctions
Remember: Prevention costs hundreds, but breakdowns cost thousands. A few minutes of daily inspection can save you from hours of delays and expensive roadside repairs.
Stay safe out there, and remember that I-35 Diesel Repair is here 24/7 when prevention isn’t enough. We’re truckers helping truckers—because we know that time is money on the road.
Need immediate help? Call our emergency line: (972) 975-7026. Average response time: 45 minutes anywhere along I-35 from Temple to Hillsboro.