How Mechanical Failures Lead to Serious Truck Accidents in Illinois

At John J. Malm & Associates, we’ve represented individuals and families across Illinois who have suffered life-changing injuries—or lost loved ones—because of careless truck drivers and negligent trucking companies. One of the most overlooked but devastating causes of truck accidents in Illinois is mechanical failure due to poor maintenance.

While most people think of truck crashes as being caused by speeding or distracted driving, the truth is that equipment failures—bad brakes, tire blowouts, steering issues—are a major factor in many serious and fatal truck accidents. When massive commercial vehicles aren’t properly maintained, everyone on the road is put at risk.

In this blog, we look at how mechanical failures contribute to truck accidents in Illinois, what the statistics say, and discuss what rights you may have if you or someone you love has been harmed in a 18-wheeler crash.

Mechanical Failures Are More Common Than You Think

It might surprise you to learn just how often trucks on the road have serious safety issues. According to the Federal Motor Carrier Safety Administration (FMCSA), about 10% of all truck accidents are caused by mechanical defects. Brakes, tires, lights, steering systems, and suspension components are some of the most common culprits.

In Illinois, the numbers are alarming. The Illinois Department of Transportation (IDOT) reported over 295,000 vehicle crashes in 2021, with more than 11,000 crashes involving tractor-trailers and over 9,000 crashes involving single-unit trucks. These crashes contributed to hundreds of injuries and fatalities across the state.

Nationally, the FMCSA’s Large Truck Crash Causation Study found that 29% of large-truck crashes involved brake issues, and 6% involved tire problems. When you consider the size and weight of these vehicles—up to 80,000 pounds—it’s easy to see how even a minor equipment issue can lead to a deadly outcome.

Common Types of Mechanical Failures in Truck Crashes

Some of the most dangerous mechanical failures we see in truck accident cases include:

1. Brake Failure

Tractor-trailers require powerful braking systems to stop safely, especially when fully loaded. But brake systems are complex and require frequent inspections and service. When trucking companies neglect brake maintenance, it can lead to failure under pressure—literally. In fact, brake-related issues are the number one mechanical factor in truck crashes nationwide.

2. Tire Blowouts

Worn, underinflated, or overloaded tires are another major hazard. A blowout at high speed can cause a truck to jackknife, roll over, or veer into another vehicle. Blowouts are often a direct result of poor maintenance or failure to follow load limits. According to the National Highway Traffic Safety Administration (NHTSA), tire-related problems have been involved in nearly one-third of all fatal large-truck crashes.

3. Steering and Suspension Problems

Trucks need stable and responsive steering systems to operate safely. If a truck’s steering linkage is loose or its suspension is worn down, the driver may lose control—especially on rough roads or during evasive maneuvers. These are exactly the kinds of issues that can be caught with proper inspections and timely repairs.

4. Lighting and Visibility Failures

Lights and reflectors are essential for visibility—especially at night, in poor weather, or in construction zones. Defective headlights, brake lights, or missing reflectors can prevent other drivers from seeing a truck or reacting in time to avoid a crash.

Why Truck Maintenance Matters

Truck drivers are required to perform a pre-trip inspection every time they get behind the wheel. In addition, trucking companies must follow federal regulations that mandate routine maintenance, repairs, and detailed recordkeeping. But these safety procedures are often skipped or ignored—sometimes to save money, sometimes due to pure negligence.

When a trucking company fails to inspect or repair critical components like brakes or tires, they put every other driver on the road in danger. And when maintenance logs are falsified or ignored, proving liability in court can become a key part of a personal injury case.

In fact, the Commercial Vehicle Safety Alliance reports that during roadside inspections, nearly 1 in 5 commercial trucks are taken out of service for serious safety violations. That means 20% of trucks on the road may have a mechanical issue that’s bad enough to sideline the vehicle immediately.

The Statistics Paint a Grim Picture

Let’s put it in perspective:

• 29% of truck crashes involve brake problems.
• Tire blowouts contribute to thousands of crashes annually—with an increasing trend over the last decade.
• 5% of all fatal large truck crashes involve a mechanical issue as a contributing factor.
• In Illinois alone, over 11,000 tractor-trailer crashes occur each year—and a significant portion involve vehicles with documented mechanical issues.

These are not small numbers. Mechanical failure is one of the top contributors to fatal truck crashes—and it’s often 100% preventable.

Who’s Responsible for Truck Failures?

When a truck accident is caused by poor maintenance, multiple parties may be held liable:

• The Truck Driver: responsible for inspecting the vehicle before and after trips.
• The Trucking Company: responsible for enforcing safety procedures and performing repairs.
• Maintenance Contractors: third-party repair shops can be liable for poor workmanship or failing to detect a problem.
• Manufacturers: if a component was defective from the start, a product liability claim may also arise.

In some cases, federal and state records—including inspection reports, maintenance logs, and recall data—can be used to prove negligence.

What to Do If You’re Involved in a Truck Accident

If you or a loved one has been injured in a truck accident in Illinois, it’s critical to act quickly. Mechanical failure cases often require in-depth investigation, accident reconstruction, and expert witnesses.

Here are some steps you can take:

1. Get medical attention immediately—even if you think your injuries are minor.
2. Preserve evidence by taking photos, getting witness information, and requesting police reports.
3. Do not speak with the trucking company’s insurer before talking to a lawyer.
4. Contact an experienced Illinois truck accident attorney who knows the complexities involving semi crashes and can begin building your case right away.

At John J. Malm & Associates, we work with seasoned investigators and engineers who can analyze truck parts, inspection records, and black box data to determine whether mechanical failure played a role in your crash.

Contact the Award-Winning Illinois Truck Accident Attorneys at John J. Malm & Associates

If you’ve been injured in a truck accident caused by mechanical failure or poor maintenance, the dedicated Naperville accident attorneys at John J. Malm & Associates are ready to fight for your rights. We have extensive experience handling complex truck accident litigation across Illinois, and we understand how to investigate mechanical issues, prove liability, and recover full compensation for our clients.

Don’t wait to take action. Contact us today for a free consultation and let us help you hold negligent trucking companies accountable.