How to Handle a Breakdown Safely on the Highway: Step-by-Step Guide

Broken truck on the road

If you’re a truck driver or fleet manager, you know that breakdowns aren’t a matter of if but when. Big rigs, busy highways, tight schedules — the margin for error is slim and the stakes are high. At Sounders Truck Repair, we believe in not just fixing trucks, but helping you avoid the worst of breakdowns, and when they do happen, handling them with safety, speed, and smart decisions. 

In this guide we’ll walk you through the full sequence: what to do immediately when your truck shows signs of trouble, the safe way to manage it on the highway, and how to minimize downtime and risk. We’ll also include tips for prevention (because future-you will thank present-you). 

Why this matters 

A breakdown on the highway for a heavy commercial truck isn’t like stalling a car in the parking lot. You’ve got 80,000+ lbs of rig, moving traffic, blind spots, and time pressures. In addition: visibility, securing the area, and exercising caution when exiting the vehicle are essential.  

So yes — this is serious business. Let’s break it down into actionable steps. 

Step-by-Step: What to do when your truck breaks down 

1. Recognize the warning signs early 

Before you’re stranded, in many cases you’ll get hints: loss of power, strange noises, overheating, a warning light, or abnormal behavior. Good fleets train drivers to “look for the signs” — checking fluids, wipers, lights, tires, etc. Read more about warning signs here  

When you sense something’s off: 

• Slow down if safe; remain calm. 

• Signal and begin moving toward the shoulder or safe zone. 

• Turn on your hazard lights — immediately.  

2. Pull off safely — to the shoulder or emergency lane 

Once you decide the truck must stop: 

• Choose the widest, flattest shoulder or breakdown lane you can reach. Avoid curves, blind spots, soft shoulders.  

• Signal your move early so other traffic understands your intentions.  

• Engage parking brakes, put the truck in neutral (if required by your procedure), turn the wheels away from traffic if on an incline.  

Learn more what to do when your truck breaks down on highway here 

3. Secure the scene & ensure maximum visibility 

This is critical, especially for heavy vehicles on busy highways. Here’s what to do: 

• Keep hazard lights on. 

• Deploy warning devices: reflective triangles, flares (if allowed), especially behind the truck at recommended distances.  

• If you must exit the vehicle, make sure you wear a high-visibility vest, exit on the side away from traffic, and move to a safe location behind a barrier if possible.  

• Stay alert. Other drivers may not expect a large rig stopped on the shoulder — don’t assume they’ll behave ideally.  

4. Assess the problem if it’s safe 

Once you and the truck are safely out of the main flow: 

• Do a quick visual inspection: check for obvious fluid leaks, tyre damage, smoke or overheating.  

• Look at instrumentation: fault codes, temperature warnings, air-brake pressure drops, etc. 

• Important: If you’re on a narrow shoulder, raising risk of collision, or if smoke or fire is present, do not remain beside the truck — get to a safe distance first.  

5. Call for professional assistance 

You’re not going to fix a major engine failure or driveline issue on the shoulder. Here’s the game plan: 

• Contact your dispatch / fleet contact and your roadside assistance provider. 

• Provide your exact location (mile marker, GPS, nearest exit) and describe the issue clearly (symptoms, what you see). 

• If there's cargo or scheduling urgency, mention it (for priority service). 

• Stay with the truck if it is safe; if not safe, move to a safer spot but keep communication lines open.  

6. Stay put — but stay alert 

While waiting: 

• Remaining in the cab is often safer (especially on elevated roadways or where other traffic might hit you) because the cab offers some protection.  

• If you must exit, face oncoming traffic, remain away from the vehicle, behind guardrails if possible. 

• Use the time to document if needed: take photos, log the incident for your fleet records. 

• Keep emergency supplies accessible (first-aid kit, water, phone charger). Some breakdowns lead to long wait times.  

7. Wait for help — prepare for delay 

Even the best roadside assist can have delays depending on location/time/weather. Instead of fretting: 

• Inform your dispatch/fleet of the delay and adjust planning accordingly. 

• Consider alternative transport or changing routing if your cargo is time-sensitive. 

• After service, do a follow-up with your fleet maintenance team about what caused the breakdown and what needs to be checked. Prevention begins here. 

8. After the incident: review and prevent 

Once you’re back on the road (or if you must switch trucks/trailers): 

• Review what happened. Was this preventable? What warning signs existed? 

• Check major systems: coolant system, battery/alternator, air brakes, tyres, engine filters — many breakdowns trace back to earlier warning signs.  

• Update your maintenance logs, and make sure the same failure won’t catch you again. 

• Communicate with your service provider (like Sounders Truck Repair) about scheduling a preventive inspection so you reduce future downtime. 

Additional Safety Considerations & Tips 

• Weather & visibility: Poor weather increases risk drastically for trucks. Slippery surfaces, reduced visibility, harder shoulder stops. Anticipate more time for problem resolution. 

• Traffic speed differential: On highways, traffic moves fast. A slow-moving or stopped truck is a major hazard. That means your margin for error is smaller — exit the traffic lane early. 

• Load/cargo considerations: If you’re carrying hazardous materials or time-sensitive loads, your decision tree changes (priority tow, specialized equipment). 

• Legal/regulation side: Always comply with state or federal breakdown protocols (e.g., placement of warning devices, wearing high-visibility gear). For example, some jurisdictions require staying buckled if you remain in the vehicle stopped on an elevated roadway.  

Read more about recommendations what to do in a roadside emergency here  

Final Word 

Breakdowns — they’re no fun. But when they happen, especially on the highway, how you respond can make the difference between a minor delay and a major incident. With the right mindset, the right steps, and a trusted partner like Sounders Truck Repair, you can handle the worst while staying as safe as possible. 

Your future-you (and your fleet budget) will thank you.