Hybrid Maintenance Is Becoming a Fleet Strategy
Findings from the 2026 NPTC Benchmarking Survey
In the 2026 National Private Truck Council Benchmarking Survey, 77% of respondents said they outsource at least part of their heavy-duty maintenance spend, and 43% rely on a combination of in-house and outsourced maintenance — the largest share this strategy has received in the survey's history.
About 24% of fleets said they are increasing the share of maintenance performed in-house, but nearly the same amount — 22% — said they are shifting more maintenance spending to outsourced providers, suggesting that carriers are becoming more deliberate about allocating maintenance resources and responsibilities.
There are several factors that can lead fleets to use more than one maintenance strategy, including mergers, technician shortages and changes in equipment acquisition strategies. For fleet managers, the challenge is determining the ideal maintenance mix that supports their needs.
Consider the Location of the Equipment
Geography can have a significant influence on maintenance decisions, particularly for fleets operating across a large network. The average private fleet in the NPTC survey operates from 48 locations.
Private fleets may have the volume and infrastructure to support an internal shop at some locations but not all, and outside maintenance resources can help extend coverage into areas where building or staffing a dedicated shop would be difficult to justify.
Assess Technician Availability
Even a well-equipped maintenance facility depends on having technicians available to perform the work, and NPTC noted that a lack of technicians in certain geographic regions can lead fleets to outsource to add capacity. That outsourcing could include turning to a dedicated provider to manage an in-house place, contracting for mobile maintenance to bring technicians and tools directly to the equipment, or coordinating work with an independent shop.
Match the Work to the Required Expertise
Different maintenance tasks can require different tools, training or technical expertise. The NPTC report found that preventive maintenance (PM) was the most reported in-house function, cited by 87% of respondents that conduct maintenance internally. Trailers, tires, brake systems, suspension and electrical work were also commonly handled in-house.
More specialized categories were less likely to remain internal. Fleets were less likely to handle work on engines, emissions equipment and refrigeration equipment in house. Just 37% said they do accident repair and body work in house.
Outside expertise can be especially valuable for repairs that require specialized tooling, diagnostics or training, and it could increase as equipment technology becomes more complex.
Make Uptime Part of the Equation
Uptime is critical, and where maintenance is performed matters less than having a strategy that keeps equipment available when the business needs it. In this year’s report, fleets achieved record preventive maintenance compliance, with 77% reporting PM currency rates of 95% or better. However, 3.4% of equipment sat idle because of unavailable maintenance or parts, and 32% of all maintenance was unscheduled.
Roadside breakdowns also increased, rising to 4.7 per 100,000 miles from 4.2 in the previous year's study. Among fleets tracking the metric, emissions and tires remained the most frequently cited causes, followed by electrical systems, brakes and cooling systems.
The right maintenance strategy can help reduce downtime. For example, outsourcing complex repairs to technicians who already have the appropriate diagnostic equipment and expertise may get the vehicle back in service faster than handling the repair internally, but performing PMs on site overnight at a high-volume terminal can reduce downtime.
Consider the Equipment Acquisition Strategy
A fleet’s acquisition strategy can also affect where maintenance takes place. For fleets using a full-service lease, maintenance is typically included in the lease. According to the report, 42% of fleets reported leasing most of their heavy-duty power equipment, up from 28% in each of the two previous years, while 34% of fleets report owning all or most of their heavy-duty equipment. The rest of respondents use a mix of leased and owned equipment.
Choose the Right Outsourcing Partner
When looking for a maintenance provider, fleets should look beyond the individual repair and consider their overall needs. Technician training and expertise, parts availability, geographic reach, preventive maintenance capabilities, roadside support, and maintenance data and reporting can all influence the long-term impact of maintenance on fleet performance.
According to the NPTC report, full-service lessors made up the largest share of outsourced maintenance spending at 43%, followed by equipment manufacturer dealer networks at 34% and independent repair facilities at 21%.
Penske offers several maintenance models that can complement an internal operation or provide a fully outsourced solution. This includes:
Maintenance on Full-Service Leases
Comprehensive maintenance is included with all of Penske’s full-service leases. Penske Truck Leasing also offers Dynamic PM®, data-driven preventive maintenance services that improve compliance, quality and uptime.
Contract Maintenance
Contract maintenance gives fleets access to Penske's maintenance network of more than 900 shops and 10,000 technicians. Fleets also get access to roadside support, data analytics, and discounted rates on tire retreading and DPF filter cleaning.
On-Site Maintenance
Fleets can bring Penske's maintenance capabilities into their facilities with on-site maintenance, allowing them to maintain the convenience of an in-house shop but tapping into Penske to manage technician recruiting, hiring, training and retention. Penske also covers the cost of maintaining parts inventory and shop equipment, and ensures safety and compliance.
Mobile Maintenance
Penske’s mobile maintenance services bring the shop to the equipment, saving time and making scheduling easier. Mobile maintenance can address PMs, schedule repairs, tire services and diagnostics. You may also be able to schedule work when equipment isn’t being used, reducing the time it is out of service.
Managed Maintenance
With managed maintenance, Penske’s ASE-certified, Penske-trained and OEM-trained specialists work with customers to coordinate PMs and repairs through a nationwide network of providers. Penske’s team fully manages the repair process and also offers 24/7 roadside assistance, negotiates rates to reduce costs and provides detailed repair information.
Collision Repair
With 65 locations across North America, Penske Collision Repair specializes in repairing medium- and heavy-duty commercial vehicles. Capabilities go beyond accident damage, and fleets can use locations for accumulated damage repair, box repair, painting, refinishing and reimaging work. Several facilities provide professional decal services.
To learn more about Penske’s maintenance options and creating a customized maintenance plan, contact us today.