•1-D numerical TEG model in diesel freight vehicles exhaust pipe.•Over 800W of electrical power for the heavy-duty vehicle.•Plain fins provide better performance than offset strip fins.•The height of the thermocouple legs plays a significant role.•2% maximum efficiency needs further improvements. A parametric study and optimization approaches of a thermoelectric generator (TEG) for the recovery of energy from the exhaust gas in Diesel vehicles used in freight transport is reported. The TEG is installed in the tailpipe of a commercial vehicle (3.5tonnes) and a heavy-duty vehicle (40tonnes). The exhaust gas is used as the heat source and the cooling water as the heat sink. Two different heat exchanger configurations are considered: plain fins and offset strip fins. The influence of the height, length and spacing of the fins on the electrical and net power is analysed for the fixed width and length of the TEG. The influence of the length and width of the TEG and of the height of the thermocouple legs is also investigated. According to the criteria used in this study, plain fins are the best choice, yielding a maximum electrical power of 188W for the commercial vehicle and 886W for the heavy-duty vehicle. The best recovery efficiency is about 2%, with an average thermoelectric material efficiency of approximately 4.4%, for the light-duty vehicle. Accordingly, there is significant room for further improvement and optimisation based on the thermoelectric modules and the system design.