Emergency Roadside Toolkit for Commercial Drivers

DOT-Required Safety Equipment

Before discussing tools and supplies, ensure your truck carries federally mandated safety equipment. FMCSA regulations require:

Warning Devices – Three reflective triangles, six fuses or three liquid-burning flares. Place triangles 10 feet, 100 feet, and 100 feet behind your vehicle (200 feet total spread) on two-lane roads, or 10 feet, 100 feet, and 200 feet on divided highways.

Fire Extinguisher – Minimum 5-B:C rating, properly charged and mounted securely. Check pressure gauge monthly. Expired or discharged extinguishers result in DOT violations.

Spare Fuses – One complete set matching all fuses in your truck, stored in a labeled container. Know fuse panel locations for lights, accessories, and critical systems.

These items aren’t optional—roadside inspections check for them, and violations result in fines and out-of-service orders.

Tier 1: Essential Hand Tools (Always Carry)

Adjustable Wrench (12-inch) – Handles most bolt sizes from 3/8″ to 1″ for mirror adjustments, battery terminals, and accessory mounts. Chrome vanadium steel resists corrosion from road salt.

Socket Set (1/2″ Drive, Metric & SAE) – 10mm through 19mm and 3/8″ through 3/4″ cover lug nuts, suspension bolts, and brake components. Include deep sockets for recessed nuts. Freightliner and Hino trucks predominantly use metric.

Ratchet & Breaker Bar – 18-inch breaker bar provides leverage for seized bolts. Pair with a quality ratchet featuring 72-tooth mechanism for tight-space work.

Screwdrivers (Flathead & Phillips) – Multiple sizes from precision electronics to heavy-duty 1/4″ shafts. Electrical panels, battery boxes, and interior components need various driver sizes.

Pliers Set – Standard slip-joint, needle-nose, and locking pliers (Vise-Grip style). Critical for electrical connections, hose clamps, and seized components.

Hammer (2 lb Ball Peen) – Tapping stuck brake drums, aligning components, and freeing frozen adjusters. Avoid excessive force that damages threads or castings.

Pry Bar (18-inch) – Separating stuck components, aligning holes, and removing hubcaps. Flat and tapered ends provide versatility.

Utility Knife & Scissors – Cutting shrink wrap, zip ties, and tape. Retractable blade prevents accidents during storage.

Tier 2: Tire & Wheel Service Tools

Tire Pressure Gauge (Heavy-Duty 0-150 PSI) – Dial or digital gauge with bleed valve. Check pressure cold (before driving) for accuracy. Medium-duty trucks typically run 80-105 PSI; heavy-duty runs 95-110 PSI.

Tire Plug Kit – Mushroom-style plugs, reamer, and insertion tool for nail holes and small punctures. Effective on tread-only damage up to 1/4″ diameter. Not suitable for sidewall damage.

Tire Inflator Hose – 25-foot coil hose with truck-style air chuck and pressure gauge. Connects to glad-hand or onboard air supply. Mandatory for every stop—verify all tire pressures daily.

Valve Core Tool – Removes and installs valve cores for quick deflation or stem replacement. Carry spare valve cores and caps.

Lug Wrench or Impact Wrench – Heavy-duty four-way lug wrench or cordless 1/2″ impact rated for 400+ ft-lbs torque. Freightliner medium-duty lugs require 450-500 ft-lbs; verify spec for your chassis.

Wheel Chocks (Pair) – Rubber or urethane chocks rated for your truck’s weight. Required whenever working under the vehicle or removing wheels.

Tier 3: Electrical & Lighting Supplies

Test Light (12V/24V) – Pierce-type test light verifies power at fuses, relays, and connectors. Essential for diagnosing lighting failures and electrical shorts.

Multimeter – Digital meter measures voltage, continuity, and resistance. Diagnose battery condition, alternator output, and sensor failures. Basic automotive meters run $25-50.

Assorted Fuses – Blade-style mini, standard, and maxi fuses covering 5A through 30A. Label a clear organizer case by amperage. Include ATO and ATC styles common in commercial trucks.

Wire Connectors & Crimp Tool – Butt connectors, ring terminals, and quick-disconnects in 14-18 gauge. Ratcheting crimp tool ensures gas-tight connections resistant to vibration and corrosion.

Electrical Tape & Heat Shrink – 3M Super 33+ electrical tape and assorted heat shrink tubing. Protect splices from moisture. Carry a lighter or heat gun for shrinking.

Spare Bulbs – Headlight, turn signal, brake, and marker light bulbs for your specific truck model. Check part numbers in owner’s manual. LED conversions reduce spare bulb needs.

Jumper Cables or Jump Box – 2-gauge cables minimum 20 feet long for truck-to-truck jumping, or a lithium jump starter rated for diesel engines (1000+ peak amps). Cold Northeast winters demand reliable jump capability.

Tier 4: Fluids & Filters

Engine Oil (1 Quart) – Match your truck’s specification (15W-40 for most diesel engines). Top-offs between service intervals prevent low-oil shutdowns.

Coolant (1 Gallon) – Pre-diluted 50/50 ethylene glycol for Detroit, Cummins, or other diesel engines. Check compatibility—some engines require specific extended-life coolants.

Power Steering Fluid – ATF Dexron III or Mercon for most hydraulic steering systems. Verify spec before topping off—wrong fluid damages pumps.

Windshield Washer Fluid (1 Gallon) – Winter formula rated to -20°F for Northeast operations. Summer formula lacks freeze protection and splits reservoirs in cold snaps.

DEF (Diesel Exhaust Fluid) – 2.5-gallon jug for SCR-equipped trucks. DEF freezes at 12°F but thaws at startup. Keep a spare jug for rural areas where DEF pumps are scarce.

Spare Oil & Fuel Filters – One set matching your truck’s service spec. If you experience fuel contamination or rapid oil consumption, roadside filter changes get you to a service facility.

Tier 5: Miscellaneous Essentials

Duct Tape & Zip Ties – Gorilla or 3M heavy-duty duct tape for temporary hose repairs, securing loose panels, and weatherproofing. Assorted zip ties from 6″ to 24″ in UV-resistant nylon.

Shop Towels & Gloves – Blue shop towels and nitrile gloves (powder-free, size L-XL). Avoid contaminating brakes or electrical connections with greasy hands.

Penetrating Oil – PB Blaster or Liquid Wrench for seized bolts and rusted fasteners. Spray threads 10 minutes before applying force to prevent breakage.

Work Light (LED Rechargeable) – 500+ lumen handheld or magnetic-mount LED work light. Lithium rechargeable avoids dead batteries. Essential for under-truck and engine bay work after dark.

Safety Glasses & Hearing Protection – ANSI Z87.1 rated safety glasses and foam earplugs. Protect eyes from battery acid, brake dust, and flying debris.

First Aid Kit – OSHA-compliant kit with bandages, antiseptic, gauze, and burn gel. Include personal medications (aspirin, antacid, pain reliever). Update expired items annually.

Bungee Cords & Ratchet Straps – Assorted sizes for securing loose cargo, tarps, or damaged components during limping to service. 1″ x 10′ ratchet straps rated 1,500 lbs working load.

Spare Glad-Hand Seals & Air Line – Red emergency and blue service glad-hand seals deteriorate from ozone and cause air leaks. Carry four spares. Include 6 feet of 3/8″ DOT air line and push-to-connect fittings for emergency line repairs.

Foldable Shovel – Compact military-style entrenching tool for digging out stuck wheels in mud or snow. Doubles as ice scraper and debris removal.

To an English person, it will seem like simplified English, as a skeptical Cambridge friend of mine told me what Occidental is. The European languages are members of the same family. Their separate existence is a myth. For science, music, sport, etc, Europe uses the same vocabulary. The languages only differ in their grammar, their pronunciation and their most common words.