DOT annual inspection checklist
Version 1 · https://conformata.io/checklists/fleet/dot-annual-inspection-checklist · Made with Conformata. Guidance, not legal advice; sources at https://conformata.io/checklists/fleet/dot-annual-inspection-checklist/sources
DOT annual inspection checklist
Free DOT annual inspection checklist built from 49 CFR 396.17 and Appendix A to Part 396: brakes, coupling, steering, tires, wheels and the report.
How often: At least once every 12 months for each commercial motor vehicle, including each unit of a combination such as a tractor, semitrailer, full trailer and converter dolly.
- Sections
- 15
- Checks
- 97
- Critical
- 23
- Sources
- 243
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Motor carrier or intermodal equipment provider operating the vehicle *
Name and address where this inspection report is kept *
Vehicle identification (unit number, VIN or serial number) *
Type of unit inspected *
TruckTruck tractorSemitrailer or full trailerConverter dollyBus or motorcoachIntermodal chassis
Date of inspection *
Odometer reading
mi
Name of the individual performing the inspection *
How the inspector meets the experience or training part of the qualification rule *
Completed a federal or state training program, or holds a state or Canadian provincial qualificationAt least 1 year of combined training or experienceInspection done under a state periodic inspection program
Air, hydraulic, vacuum and electric brakes. Mark N/A for systems the vehicle does not have.
Every axle required to have brakes has a brake, and each one shows braking action when the service brakes are applied *
YesNo
No shoes, linings, pads, springs, anchor pins, spiders, cam rollers, pushrods or air chamber mounting bolts are missing or broken *
YesNo
Air chambers, spiders and camshaft support brackets are tight, and no brake chamber leaks air audibly *
YesNoN/A
Pushrod stroke on every air brake is within the readjustment limit for its chamber type and size *
YesNoN/A
Longest pushrod stroke measured
in
Every lining and pad is firmly attached to its shoe and is not soaked with oil, grease or brake fluid *
YesNo
Linings on non-steering axles are thicker than the minimum for their brake type *
YesNoN/A
Linings on steering axles are thicker than the minimum for their brake type *
YesNoN/A
Air chamber sizes and slack adjuster lengths match on both sides of each power unit steering axle
YesNoN/A
Wedge brakes: the scribe mark on the lining has moved no more than 1/16 in
YesNoN/A
Applying the parking brake control applies brakes on the vehicle or combination *
YesNoN/A
Drums and rotors have no external cracks that open when the brake is applied and no pieces missing or about to fall away *
YesNo
Brake hoses have no damage through the outer reinforcement ply, no bulging under air pressure, no audible leaks, no improper splices and no cracks, breaks or crimps *
YesNoN/A
Brake tubing has no audible leak and is not cracked, heat-damaged, broken or crimped *
YesNoN/A
Low air pressure warning device is fitted and operates at 55 psi, or at half the governor cut-out pressure if that is lower *
YesNoN/A
Tractor protection valve on the power unit is fitted and works
YesNoN/A
Air compressor belts are not close to failure, and its mounting bolts, pulley and brackets are tight and uncracked
YesNoN/A
Electric brakes act on every wheel required to have brakes, and the breakaway braking device is fitted and works
YesNoN/A
Hydraulic brakes: master cylinder at least 1/4 full, pedal reserve without pumping with the engine running, and the power assist unit works
YesNoN/A
Hydraulic brakes show no visible fluid leak, no seeping or swelling hoses under pressure, and no leaking, restricted, crimped, cracked or broken lines
YesNoN/A
Hydraulic brake check valve is present and works, and no hydraulic hose is chafed through the outer cover to the fabric layer
YesNoN/A
Brake failure or low fluid warning light is off and works
YesNoN/A
Vacuum system keeps enough reserve for one full brake application after the engine is shut off, its hoses are sound, and the low-vacuum warning device works
YesNoN/A
ABS malfunction lamp and its bulb and wiring are present, the lamp lights when power is first applied, and it does not stay on while power stays applied *
YesNoN/A
Trailer or dolly ABS lamp cycles on constant power and on stop-lamp power, and the power unit supplies constant power to the ABS of air-braked units it tows
YesNoN/A
No other ABS components are missing or inoperative
YesNoN/A
Automatic brake adjusters keep each brake within the maker's stroke limit, none has been swapped for a manual adjuster, and none has damaged, loose or missing parts *
YesNoN/A
Mark N/A for coupling devices the unit does not have.
Fifth wheel mounting to the frame has no missing or ineffective fasteners, no movement between mounting parts and no cracked or broken angle iron *
YesNoN/A
Mounting plates and pivot brackets have no missing fasteners or cracked welds, the pivot pin is secured, and pin-to-bracket horizontal play is 3/8 in or less *
YesNoN/A
Sliding fifth wheel has all latching fasteners and fore and aft stops, no cracks, and no more than 3/8 in play between slider bracket and base
YesNoN/A
Upper and lower fifth wheel halves move no more than 1/2 in horizontally, the operating handle is closed and locked, and the locking parts hold the kingpin securely *
YesNoN/A
No light shows between the upper and lower coupler from side to side, and the fifth wheel plate has no cracks
YesNoN/A
Pintle hook is tightly mounted with no cracks at the frame or cross member, no cracks or welded repairs in the hook, no more than 20% wear on the horn section, and a secure latch *
YesNoN/A
Drawbar or towbar eye has no cracks in the eye or its attachment welds, no missing or ineffective fasteners, and no part worn down by more than 20% *
YesNoN/A
Drawbar or towbar tongue has no cracks and moves less than 1/4 in at its subframe attachment; any slider has a working latch and stop, less than 1/4 in play, and no leaking air or hydraulic cylinders, hoses or chambers *
YesNoN/A
Safety chains or cables are present and securely attached, chains have no measurable link wear or improper repairs, and cables have no kinked or broken strands or improper clamps *
YesNoN/A
Saddle-mounts have no missing fasteners, loose mountings or cracked load-bearing members, and the halves move no more than 1/4 in horizontally
YesNoN/A
Exhaust does not leak at any point forward of or directly below the driver or sleeper compartment *
YesNoN/A
Bus exhaust leaks or discharges no more than 6 in forward of the rear (gasoline) or 15 in (other fuels), and never forward of a door or window that opens
YesNoN/A
No part of the exhaust is placed where it could burn, char or damage wiring, the fuel supply or any combustible part *
YesNoN/A
No visible fuel leak anywhere in the fuel system *
YesNoN/A
Every fuel tank has its filler cap *
YesNoN/A
Fuel tanks are securely attached with no loose, broken or missing mounting bolts or brackets *
YesNoN/A
Every lighting device and reflector that 49 CFR Part 393 requires on this vehicle is operable *
YesNo
Nothing about the vehicle or the load lets the spare tire, cargo or dunnage fall onto the roadway *
YesNo
A front-end structure or equivalent device is fitted where one is needed to protect against shifting cargo
YesNoN/A
Intermodal container securement devices (rails, support frames, tiedown bolsters, locking pins, clevises, clamps, hooks) are not cracked, broken, loose or missing
YesNoN/A
Steering wheel free play is within the limit for the wheel's diameter *
YesNoN/A
Steering wheel free play measured
in
Steering column U-bolts and positioning parts are present and tight, universal joints are not worn, faulty or repair-welded, and the steering wheel is secure *
YesNoN/A
Front axle beam and steering components other than the column have no cracks and no obvious welded repairs *
YesNoN/A
Steering gear box mounting bolts are all present and tight, with no cracks in the box or its brackets *
YesNoN/A
Pitman arm is tight on the gear output shaft, and any auxiliary power assist cylinder is secure
YesNoN/A
Ball and socket joints show no stud nut movement under steering load and no non-rotational play over 1/4 in; tie rod and drag link clamps, threaded joints and nuts are tight *
YesNoN/A
No modification or other condition interferes with free movement of any steering component *
YesNoN/A
U-bolts, spring hangers and other axle positioning parts are sound and tight, and no axle has shifted from its normal position *
YesNo
No leaf spring leaves broken or missing, no broken main leaf, coil spring or torsion bar, no rubber spring missing, and no leaf displaced toward a tire, rim, drum or frame *
YesNoN/A
Air suspension is inflated with no system failure or leak
YesNoN/A
Torque, radius and tracking components and their attaching parts are not cracked, loose, broken or missing *
YesNoN/A
No frame member is cracked, broken, loose or sagging *
YesNo
No loose or missing fasteners, including those that attach the engine, transmission, steering gear, suspension, body and fifth wheel *
YesNo
The body and frame do not touch any tire or wheel part, including when loaded *
YesNo
Adjustable axle assembly (sliding subframe) locking pins are present and engaged
YesNoN/A
Shallowest tread on a power unit steering axle tire, in 32nds of an inch
Power unit steering axle tires have at least 4/32 in tread in every major groove, no exposed ply or belt, no tread or sidewall separation and no cut exposing ply or belt *
YesNoN/A
Steering axle tires are not marked 'Not for highway use', not repaired with a boot or blowout patch, not mixed bias and radial on the axle, and not regrooved unless used only in urban or suburban service *
YesNoN/A
Steering axle tube-type radial tires have radial tube stem markings, and no tire flap sticks through the rim's valve slot and touches the stem
YesNoN/A
Bus steering axle tires are not recapped or retreaded
YesNoN/A
Shallowest tread on any other tire, in 32nds of an inch
All other tires have at least 2/32 in tread in every major groove, no exposed ply or belt, no separation, no cut exposing ply or belt, and no 'Not for highway use' marking *
YesNo
No tire is flat, audibly leaking, carrying more than its load limit (including from low pressure) or touching the vehicle or its mate *
YesNo
No speed-restricted tires are fitted unless the motor carrier has specifically designated them *
YesNo
Lock and side rings are not bent, broken, cracked, sprung, mismatched or improperly seated *
YesNoN/A
Wheels and rims are not cracked or broken and have no elongated bolt holes *
YesNo
No wheel fasteners (spoke or disc) are loose, missing, broken, cracked, stripped or otherwise ineffective *
YesNo
No cracked disc-to-rim or rim-to-adapter welds, and no welded repairs on steering axle aluminum wheels or steering axle steel disc wheels (other than the disc-to-rim weld) *
YesNo
In the inspected windshield area, no crack is wider than 1/4 in or crossed by another crack, and no damaged spot is over 3/4 in across or within 3 in of another *
YesNoN/A
No discoloration or other vision-reducing matter in the inspected windshield area
YesNoN/A
Every windshield wiper on the power unit works and has no missing or damaged parts that make it ineffective *
YesNoN/A
Every motorcoach passenger seat is securely fastened to the vehicle structure
YesNoN/A
Rear impact guard rule that applies to this vehicle
Trailer or semitrailer of 10,001 lb GVWR or more built on or after January 26, 1998Other commercial motor vehicle built after December 31, 1952Excepted under 49 CFR 393.86 or no guard rule applies
Rear impact guard is present and securely attached, with no broken or missing fasteners and no cracked welds or parent metal
YesNoN/A
Newer trailer guard: bottom no more than 22 in above the ground, within 4 in of each side without sticking out, no more than 12 in forward of the rear, and at least 4 in tall across its width
YesNoN/A
Other vehicle guard: no more than 30 in above the ground, within 18 in of each side and no more than 24 in forward of the rear
YesNoN/A
Components that do not meet the Appendix A standard, and what is wrong with each *
Inspection result *
Passed: every component meets the Appendix A standardDid not pass: repair and re-inspect the listed components
Proof of this inspection is on the vehicle: this report, or a sticker or decal showing the date, where the report is kept, the vehicle identity and a pass statement
YesNoN/A
The original or a copy of this report is filed where the vehicle is housed or maintained *
YesNo
Inspector's certification
Sign the printed copy, or sign electronically in Conformata.
I performed this inspection, and this report is accurate and complete and identifies every component that does not meet the minimum periodic inspection standards.
Signature
Name and date
Run it with your team in Conformata
- Schedule it per site and assign it to the right people.
- Turn every failed check into a corrective action that someone else verifies.
- Keep signatures, photos and the full audit history across sites.
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Frequently asked questions
How often is a DOT annual inspection required?
At least once every 12 months. A vehicle may not be used unless each Appendix A component passed an inspection at least once during the preceding 12 months and documentation of it is on the vehicle [216].
Who is allowed to do a DOT annual inspection?
A motor carrier may inspect vehicles under its own control [223], or use a commercial garage, fleet leasing company, truck stop or similar business as its agent [224]. Either way the inspector must meet all three parts of the qualification rule. They must understand the inspection criteria in Part 393 and Appendix A and be able to identify defective components [228]. They must know and have mastered the methods, procedures, tools and equipment used in an inspection [229]. And they must be capable by experience, training or both: either a federal or state training program or a certificate from a state or Canadian province [230], or at least 1 year of combined training or experience [231].
How long do I keep the annual inspection report?
Does a state vehicle inspection count as the DOT annual inspection?
It can. A vehicle that passes a periodic inspection under a state government program [226] that meets the Appendix A minimum standards is treated as having met the annual inspection requirement for 12 months, counted from the last day of the month of the inspection [225]. You do not need to keep inspector qualification records for inspections done under a state periodic inspection program [233].
Built from 243 official sources
Every check traces to the text it is based on. Read the purpose, how to use it, the rules behind it, what it does not cover and every source.
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Guidance, not legal advice. It does not replace the law, the manufacturer's instructions or your organization's competent people, and completing it does not certify that work is safe.