DOT Annual Inspection Prep Checklist

The direct answer: a truck that gets a PM and a walk-through against this list before its federal annual inspection rarely fails it, because the inspection checks the same systems the PM already measured. Work through each item, fix what fails, and bring the paperwork. The inspection itself follows Appendix A to Part 396; the limits quoted here come from Part 393. Print this page and keep one per unit — tractors and trailers each need their own inspection.

Paperwork to bring

• ☐ The previous annual inspection report for this unit (reports are kept 14 months — 396.21)
• ☐ Any open DVIR defects and their repair certifications (DVIR rules)
• ☐ Unit number, VIN and current mileage or engine hours
• ☐ For California BIT carriers: where this unit is in its 90-day cycle (BIT program)

Brakes and air system

• ☐ Lining or pad thickness at every wheel end — steer drum linings at least 3/16 in. (1/4 in. two-pad), other air drum linings at least 1/4 in., air disc pads at least 1/8 in. (limits)
• ☐ Applied pushrod stroke within each chamber’s readjustment limit; slack adjusters working
• ☐ Chambers and slack adjusters matched side to side on each axle
• ☐ Drums and rotors free of cracks and within discard dimension; no oil on linings (wheel seals)
• ☐ No audible air leaks; hoses and lines not chafed, kinked or flattened
• ☐ Low-air warning comes on before pressure falls below 60 psi (FMVSS 121)
• ☐ Parking (spring) brakes hold and release fully; gladhands and seals intact
• ☐ ABS lamp goes out after the bulb check, tractor and trailer (ABS light)

Steering and suspension

• ☐ Steering wheel lash within the limit for the wheel diameter — with power steering, 4 1/4 in. on a 16-in. wheel up to 5 3/4 in. on a 22-in. wheel (393.209; see hard steering)
• ☐ No looseness at tie-rod ends, drag link, pitman arm or kingpins; steering gear box mounted solid
• ☐ Power steering: no leaks, belts sound, fluid at level
• ☐ Springs not cracked or shifted; air bags holding; U-bolts and torque rods tight

Tires, wheels and rims

• ☐ Steer tires at least 4/32 in. in a major groove; all others at least 2/32 in. (tread minimums)
• ☐ No exposed cord, tread or sidewall separation, cuts to the cord, or audible leaks
• ☐ Duals matched for size and pressure; nothing lodged between them
• ☐ Wheels and rims not cracked or bent; no missing or loose lug nuts; no rust streaks from studs

Lights and electrical

• ☐ Every required lamp works: headlamps, tail, stop, turn, hazard, clearance, marker and identification lamps
• ☐ Reflectors and conspicuity tape present and clean
• ☐ Seven-way connector and trailer harness secure, not chafed (trailer lights)
• ☐ Batteries secured and terminals clean

Coupling, frame, exhaust and fuel

• ☐ Fifth wheel locks properly; kingpin and upper coupler not worn or damaged; mounting bolts tight
• ☐ Frame rails and cross-members free of cracks and loose fasteners
• ☐ Exhaust system: no leaks under the cab, mounted securely, not routed against wiring or fuel lines
• ☐ Fuel tanks secured, caps present, no leaks (identify a leak)

Cab and safety equipment

• ☐ Windshield free of damage in the driver’s view; wipers and washers work
• ☐ Horn works; mirrors secure and adjusted
• ☐ Fire extinguisher mounted, charged and rated (5 B:C, or two 4 B:C) (emergency equipment)
• ☐ Three reflective triangles (or at least six fusees) aboard

After the inspection

A passed unit gets a completed report and proof of inspection carried on or with the vehicle, as 396.17 requires, and the report is kept for 14 months. A failed item is repaired and the inspection completed — which is why having the inspection and the repair under one roof saves a second trip. Our DOT inspections are done in our North Highlands bays, and repairs found during inspection happen in the same visit when possible. The full rule in plain English is in DOT inspection requirements.

Common questions

How far ahead should I do this checklist?

A week or two before the inspection date leaves time to order parts for anything that fails. Fleets fold it into the PM that comes before each unit’s annual so nothing is done twice.

Can I use this checklist as my DVIR?

No. A DVIR is the driver’s end-of-day report under 396.11, with its own required items and repair certification. This checklist is preparation for the annual inspection; it does not replace either the DVIR or the inspection itself.

Does every trailer need its own annual inspection?

Yes. Every power unit and every trailer in interstate commerce over the weight threshold carries its own periodic inspection, report and proof. A current tractor pulling an expired trailer is still a violation.

What fails most often?

Brakes — adjustment and lining wear — and lighting are consistently among the most-cited items at roadside, and they are the first two sections on this list for that reason.

General guidance citing the Federal Motor Carrier Safety Regulations as published on eCFR, reviewed 2026-10-18. It is a preparation aid, not legal advice or a substitute for the inspection.