Used heavy rigids and semis are practical for growing operators, especially when cash flow is tight or a quick expansion is needed. But buying a truck is rarely just about what’s written on the windscreen. Whether it’s mechanical condition, compliance, or what’s hidden in the paperwork, many buyers miss critical red flags.
For anyone operating a freight company, these mistakes are more than inconvenient. They can result in failed inspections, insurance issues, or trucks being parked up just weeks after purchase. Worse still, reputations and customer commitments are often on the line before the first load even leaves the yard.
“We’ve seen trucks come in looking tidy, only to find mismatched compliance records, missing mod plates, or signs of quick patch-up jobs,” says William Nguyen, Senior Allocator at a Transport Company. “It’s not just about roadworthiness. It’s about whether the truck will hold up to the work.”
Below are the most common issues buyers overlook and how to avoid them.
Odometer readings that don’t add up
Digital odometers might seem harder to tamper with, but they still get altered more often than people realise. A truck showing 600,000 km but missing service records for two or three years should set off alarms. Some units also have cluster swaps without notation, meaning the dash doesn’t match the driveline’s real usage.
How to avoid it:
- Cross-check kilometres against service logs, oil change intervals, and any existing defect reports.
- Ask for inspection paperwork from known mechanics or service chains.
Repaired vehicles without declared damage
Not all damage ends up on a write-off register. Some trucks get involved in incidents, receive fast repairs, and go straight back to market. A new paint job or aligned body panels can cover signs of structural fatigue, especially on vehicles coming out of high-pressure linehaul roles.
What to do:
- Inspect underneath for signs of chassis rail rework, weld marks, or uneven surface prep.
- Check door gaps and alignment around the cabin to spot signs of previous bending or impact.
- Bring in a heavy vehicle mechanic to conduct a full body and driveline inspection before committing.
Unapproved modifications that can void registration
From suspension adjustments to GVM upgrades and turntable installations, many trucks are sold with modifications that don’t have proper engineering sign-off. Just because the change exists doesn’t mean it’s legal. Some sellers even cover or remove mod plates altogether to avoid scrutiny.
What to check:
- Ensure the modification plate is present, legible, and matches what’s been advertised.
- Ask for the engineering certificate, especially for brake system changes or chassis alterations.
- Confirm the truck still meets ADR and NHVR standards for your intended operating class.
Finance owing and title problems
Buying a truck with money still owing on it is more common than most people realise. If a truck is under finance and sold without a proper discharge, the financier can repossess it, regardless of whether you’ve paid the seller. The same goes for trucks that were stolen, rebirthed, or illegally re-registered.
How to protect yourself:
- Ask for proper proof of ownership. A rego paper isn’t always enough.
- Be cautious with interstate purchases where seller details don’t match registration records.
Rego isn’t the same as being road-legal
A registered truck can still fail an inspection. Conditional registrations or lapses in inspection compliance are often ignored by private sellers. Some trucks are moved between states to avoid strict HVIS or defect checks, meaning you inherit the compliance problem without knowing it.
What to confirm:
- Request the most recent HVIS or equivalent roadworthiness report, and check for outstanding defects.
- Review whether the truck’s registered usage class matches your business use.
- If operating in New South Wales or Queensland, make sure it meets state-specific PBS or axle spacing requirements.
Cosmetic work that covers deeper problems
Trucks that have worked in corrosive environments, coastal regions, agriculture, or chemical sites often develop chassis and subframe corrosion. Sellers may repaint or undercoat the affected areas to mask this. New tyres and fresh mudguards may look good, but they say nothing about suspension health, driveline wear, or fatigue in key components.
What to watch for:
- Rust bubbling under surface paint, especially near suspension mounts or cross-members.
- Non-factory paint textures or overspray in hidden areas.
- Inconsistent surface finish underneath the cabin or near the turntable.
Missing maintenance means real risk
Trucks that have gone long periods without proper servicing often present well but fail early. Cooling systems, clutches, alternators, and gearbox synchronisers wear gradually. If the last few years of maintenance aren’t documented, you’ll likely inherit a list of problems.
How to mitigate this:
- Ask for full maintenance logs. If the truck came from a fleet, there should be electronic records or workshop summaries.
- Confirm the timing of major component services, particularly cooling systems and clutch assemblies.
- If the engine bay looks overly clean, ask why. A full steam clean without reason may hide leaks or residue.
The insurance claim you never hear about
Less commonly discussed, but just as damaging, is insurance-related fraud in the truck market. Some trucks enter the second-hand market after being involved in staged or suspicious insurance claims. These include trucks reported stolen but quietly sold off, or vehicles written off in deliberately exaggerated incidents. A small number may have even been reinsured after damage and claimed under a newer policy.
“We’ve heard of trucks that were allegedly stolen and then popped up on the market six months later,” says William. “It’s rare, but the damage isn’t always physical; it’s in the paperwork.”
What to do:
- Ask where the truck has been stored or operated since the last recorded registration or service.
- Be cautious of trucks that seem underpriced, rushed, or come with vague histories from third-party sellers.
Final thought
If you’re running or building a freight company, the real cost of a truck isn’t just what you pay upfront. It’s the ongoing cost of poor reliability, failed inspections, and disputes over compliance or ownership. And once it’s in your books, you own the outcome.
“We treat every truck as if it’s going to do 1,000 kilometres tomorrow. If it can’t manage that without uncertainty, it’s not ready for the job,” says William Nguyen.
A proper truck purchase is part inspection, part investigation. Take the time to check it properly, or be prepared to spend twice fixing what the last person ignored.
