5 Common Dry Van & Reefer Trailer Problems

Dry van and reefer trailers are the backbone of the trucking industry, moving everything from dry goods to temperature-sensitive products across the country. Whether you’re hauling general freight or perishable items, your trailer must stay in peak condition to avoid costly breakdowns and delivery delays. However, like any heavy-duty equipment, trailers are prone to various mechanical and structural issues.

Understanding these common dry van and reefer trailer problems can help you stay ahead of potential breakdowns and keep your fleet running smoothly. Here are five of the most common issues you might encounter and how to prevent them.

1. Trailer Roof Leaks

One of the most frequent issues with dry van trailers is roof leaks, which can allow water to seep into the cargo area. This can result in damaged freight, mold growth, and even structural deterioration of the trailer over time. To prevent leaky roofs, regularly inspect the roof for signs of wear, including cracks, rust, and loose rivets. Also, apply a high-quality sealant around seams and rivets to prevent water from entering. It’s best to store trailers in covered areas when not in use to reduce weather-related deterioration. Roof leaks typically develop due to:

• Weather exposure: Constant exposure to sun, rain, and snow can weaken the roofing material.
• Wear and tear: Over time, small cracks and punctures can form due to road debris or low-hanging branches.
• Improper sealing: Seams and rivets can become loose, leading to water intrusion.

2. Floor Damage and Weakness

Dry van trailers are constantly subjected to heavy loads and frequent loading/unloading, which can cause floor damage over time. Adhere to the manufacturer's recommended load limits to prevent floor stress and inspect the floor for soft spots, warping, and cracks after every trip. To protect against floor damage you can also use protective mats or plywood when loading heavy equipment to distribute weight more evenly.Common causes that can damage or weaken your trailer’s floor include:

• Overloading: Exceeding weight limits can lead to cracks, warping, and weakening of the floor structure.
• Moisture intrusion: Water that enters through damaged seals or doors can weaken the wood or composite flooring.
• Forklift operations: Repeated forklift use can create concentrated stress points, leading to cracks or soft spots.

3. Reefer Unit Malfunctions

For reefer trailers, the refrigeration unit is the heart of the operation, ensuring temperature-sensitive cargo stays within the required conditions. However, these units are prone to several issues, such as:

• Compressor failure: A faulty compressor can lead to insufficient cooling, causing cargo spoilage.
• Sensor malfunctions: If the temperature sensors fail, the unit may not maintain the correct cooling levels.
• Fuel issues: Running out of fuel or clogged fuel lines can result in the unit shutting down unexpectedly.

Some tips to prevent reefer malfunctions include:

• Schedule regular preventive maintenance, including checking refrigerant levels and cleaning filters.
• Testing sensors and electrical components before each trip to ensure they function properly.
• Keep an eye on fuel levels and inspect the fuel lines for blockages or leaks.

4. Door Seal Failures

Both dry van and reefer trailers rely on door seals to keep cargo safe from external elements. Over time, these seals can wear out, crack, or tear, leading to issues such as:

• Temperature loss: In reefer trailers, broken seals allow warm air to enter, forcing the reefer unit to work harder and increasing fuel consumption.
• Moisture intrusion: Damaged seals can let water into the trailer, potentially damaging sensitive cargo.
• Pest infestations: Small gaps in the seal provide entry points for insects and rodents.

Prevention tips:

• Inspect door seals regularly for cracks, tears, and gaps.
• Replace damaged seals promptly to maintain cargo integrity.
• Lubricate seals with silicone-based products to prevent drying and cracking.

5. Brake System Issues

Trailer brakes are critical for safe operations, and when they fail, they pose a significant risk to drivers and cargo. You should conduct thorough pre-trip inspections of the brake system, looking for air leaks and worn components. It’s best to replace brake shoes and drums according to the manufacturer’s recommendations. Some common brake-related issues include:

• Air leaks: In air brake systems, leaks can cause a loss of braking power, making it difficult to stop the trailer effectively.
• Worn brake pads and drums: Over time, brake pads and drums wear down and may need replacement to maintain stopping power.
• Slack adjuster problems: Manual slack adjusters need to be adjusted regularly, while automatic slack adjusters can fail if not properly maintained.

Preventive Maintenance: The Key to Avoiding Trailer Problems

While it’s impossible to prevent every single issue, routine preventive maintenance can significantly reduce the likelihood of breakdowns. Create a maintenance schedule that includes:

• Pre-trip inspections: Check key components like tires, brakes, and reefer units before hitting the road.
• Post-trip inspections: Document any damages or wear that occurred during transit.
• Seasonal maintenance: Adjust inspections and repairs based on weather conditions, such as preparing for winter or summer operations.

Prevent Trailer Breakdowns with Proper Maintenance

Keeping your dry van or reefer trailer in top condition requires vigilance and a proactive approach to maintenance. By staying aware of potential issues like roof leaks, reefer unit failures, and brake problems, you can minimize downtime and protect your cargo. Regular inspections, preventive maintenance, and professional repairs when necessary will ensure your trailers stay roadworthy and reliable.If you need expert help maintaining your fleet, don’t hesitate to contact S&D Auto & Truck in Cumberland, RI. Their skilled team is ready to assist with all your trailer maintenance and repair needs. To learn more about heavy-duty trucks, read our article on trailer maintenance. ‍