DOT Inspection Checklist

You see the lights in your mirror. State trooper. You pull over.

"Routine DOT inspection," he says.

Your heart races. Did you check everything this morning? Fire extinguisher mounted? Triangles in the box? Oil level good? When did you last check tire tread depth?

90 minutes later, he hands you a citation. "Brake adjustment out of spec on axle 3. You're out of service until it's fixed."

Now you're sitting at a truck stop waiting for a mobile mechanic,

your delivery is late, and you just got CSA points that'll follow you for years.

This guide shows you exactly what DOT inspectors check, what violations put you out of service, and how to pass inspections without citations.

The 3 Main DOT Inspection Levels

There are 8 DOT inspection levels total, but 3 matter most for owner-operators:

Level 1: North American Standard Inspection (Most Common)

What it is: The most comprehensive roadside inspection. Inspector checks both vehicle AND driver.

How long it takes: 60-90 minutes

What they check:

• All driver documentation (license, medical card, HOS logs)
• Complete vehicle inspection (37-step procedure)
• Under the vehicle (brake systems, suspension, frame)
• Inside the vehicle (seatbelts, fire extinguisher, ELD)
• Cargo securement
• Alcohol/drug check (if suspicion exists)

When it happens:

• Weigh stations
• Roadside enforcement
• Random selection
• After accidents
• When carrier has poor safety rating

Most thorough. Most time-consuming. Most likely to find violations.

Level 2: Walk-Around Inspection

What it is: Same as Level 1, but inspector doesn't go under the vehicle.

How long it takes: 30-45 minutes

What they check:

• Driver documentation (same as Level 1)
• Vehicle exterior walk-around
• Lights, tires, windshield, wipers
• Cargo securement (visible from outside)
• Does NOT check suspension, brake systems, frame (things requiring getting under truck)

When it happens:

• Quick roadside checks
• Weigh stations with high traffic
• When time is limited

Faster than Level 1, but still catches most common violations.

Level 3: Driver/Credential Inspection (Driver-Only)

What it is: Inspector checks driver documents ONLY. No vehicle inspection.

How long it takes: 10-15 minutes

What they check:

• Commercial driver's license (CDL)
• Medical certificate
• Hours-of-service logs (ELD or paper)
• Driver qualification file documents (if applicable)
• Alcohol/drug testing records (if applicable)

When it happens:

• Quick checks at weigh stations
• Traffic stops
• Checkpoints

Fastest inspection. Only affects driver, not vehicle.

Most common result: HOS violations (if you're over hours).

Common DOT Violations (What Gets You Cited)

From research and forums:

Brake-related problems are by a wide margin the leading cause of vehicle violations.

If 20% or more of your service brakes have a defect, you're automatically out of service. For a standard 5-axle tractor-trailer with 10 brakes, that means if just 2 are bad, you're parked.

Top Vehicle Violations

1. Brake System Issues (Leading Cause of OOS)

What they check:

• Brake adjustment (pushrod travel)
• Air leaks from chambers, hoses, or fittings
• Cracked brake drums or rotors
• Brake pad/shoe thickness
• Slack adjusters

Out-of-service criteria:

• 20% or more brakes out of adjustment
• Any audible air leak
• Crack in brake drum/rotor that runs to edge
• Brake pad thickness below minimum

Example: Your truck has 10 brakes. Inspector finds 2 with excessive pushrod travel (out of adjustment). 20% threshold met = out of service.

2. Tire Violations

What they check:

• Tread depth (minimum 2/32" on steer tires, 4/32" on drive/trailer in some states)
• Tire pressure
• Sidewall damage, bulges, exposed cords
• Tire size mismatches on same axle

Out-of-service criteria:

• Any steer tire with less than 4/32" tread
• Tire with exposed cord or fabric
• Flat tire
• Tire rubbing on vehicle
• Regrooved tire on steer axle

From real violation: Steer tire at 3/32" tread depth. Legal minimum is 4/32". Out of service until tire replaced.

3. Lighting Violations

What they check:

• Headlights (both low and high beam)
• Brake lights
• Turn signals
• Clearance lights
• Marker lights
• License plate light

Out-of-service criteria:

• 50% or more stop lamps inoperative
• Both headlights out
• All turn signals on one side out

Common mistake: One brake light bulb out (not OOS), but you get a citation and it goes on your CSA score.

4. Windshield and Wipers

What they check:

• Cracks in windshield (especially in driver's viewing area)
• Wiper blade condition
• Washer fluid operational

Out-of-service criteria:

• Crack longer than 11 inches
• Crack in driver's sight line (area cleared by wipers)
• Wiper blade missing or ineffective

5. Cargo Securement

What they check:

• Number of tie-downs (minimum required based on cargo weight/length)
• Tie-down condition (no cuts, fraying, damage)
• Proper tensioning
• Load not shifted or leaning

Out-of-service criteria:

• 50% or fewer required tie-downs in use
• Loose cargo that could fall or shift

Example: Load requires 6 tie-downs. You have 4. You have 66% (more than 50%) = Citation but not OOS. Load requires 6 tie-downs. You have 2. You have 33% (less than 50%) = Out of service.

Top Driver Violations

1. Hours of Service (Most Common Driver Violation)

What they check:

• Current HOS status (can you legally drive right now?)
• Last 7-8 days of logs
• Compliance with 11-hour, 14-hour, 60/70-hour rules
• 30-minute break requirement
• 10-hour off-duty requirement

Out-of-service criteria:

• Driving beyond 11-hour limit
• Driving after 14-hour window expires
• Not enough off-duty time before current trip

From TruckersReport forums:

"HOS violations are the #1 reason drivers are placed out of service - nearly 32% of all driver-related violations."

2. Medical Certificate Expired

What they check:

• Valid medical examiner's certificate (Med Card)
• Expiration date
• Certificate restrictions match actual operation

Out-of-service criteria:

• Expired medical certificate
• No medical certificate
• Certificate doesn't cover vehicle type you're operating

Simple mistake, automatic OOS.

3. ELD Malfunctions Not Documented

What they check:

• ELD is certified and compliant
• ELD functioning properly
• If malfunctioning, proper documentation of malfunction and use of paper logs

Out-of-service criteria:

• No ELD when required
• ELD malfunctioning for more than 8 days without proper paper log backup
• ELD not certified

4. False Logbook / Falsifying Records

What they check:

• Logs match actual driving (cross-reference fuel receipts, toll records, GPS)
• No evidence of two log books
• ELD data not tampered with

Out-of-service criteria:

• Clear evidence of falsified logs
• Running two sets of logs
• Tampering with ELD

Penalty: Up to $15,846 fine for knowing falsification. Plus criminal charges possible.

Pre-Trip Inspection Checklist (Do This EVERY Day)

This is your defense against DOT violations.

Documents (Keep in Cab)

• Commercial Driver's License (CDL) - current, valid
• Medical Examiner's Certificate - not expired
• Vehicle registration
• Proof of insurance
• IFTA decals (if applicable)
• Permit book (if hauling oversize/overweight)
• Previous 7 days of HOS logs available

Engine Compartment

• Oil level (check dipstick)
• Coolant level (when engine COLD)
• Power steering fluid
• Windshield washer fluid
• Belt condition (no cracks, fraying, or excessive wear)
• Hoses (no cracks, bulges, or leaks)
• No fluid leaks visible

Lights (All Must Function)

• Headlights (low and high beam)
• Turn signals (front and rear, both sides)
• Brake lights (all bulbs working)
• Tail lights
• Clearance lights
• Marker lights
• License plate light
• Hazard lights

Pro tip: Walk around truck with hazards on, then walk around with turn signals on (left, then right), then have someone press brakes while you check rear.

Tires (Check All 18)

• Tread depth minimum (4/32" steer, 2/32" drive/trailer minimum)
• Proper inflation (check with gauge, not just visual)
• No cuts, bulges, or exposed cords
• Valve caps present
• No tire rubbing on vehicle
• Lug nuts tight (tap with wrench - loose nuts sound different)

How to check tread depth: Use penny test: Insert penny (Lincoln's head upside down) into tread. If you see top of Lincoln's head, tread is below 2/32".

For steer tires, use quarter (Washington's head). If you see top of head, below 4/32".

Brakes

• Air pressure builds to 120+ PSI within reasonable time
• No air leaks audible when brakes applied
• Brake pedal firm (not spongy)
• Parking brake holds
• Trailer brakes function (tug test)
• No visible brake fluid leaks

Test parking brake: Set parking brake, put truck in gear, try to move. Truck should NOT move.

Test service brakes: Build air to 120 PSI, press brake pedal and hold. Watch gauge. Should not drop more than 3 PSI in one minute.

Windshield and Wipers

• No cracks longer than 11 inches
• No cracks in driver's sight line (directly in front of steering wheel)
• Wiper blades intact (no tears or missing rubber)
• Wipers function on all speeds
• Washer fluid sprays

Frame and Suspension

• No cracks in frame
• U-bolts tight
• Spring hangers secure
• No broken or cracked springs
• Shock absorbers secure (no leaking)

Coupling (Tractor-Trailer)

• Fifth wheel locked (tug test - pull forward with brakes set)
• No visible gap between upper and lower fifth wheel
• Fifth wheel properly greased
• King pin not bent or worn
• Air lines connected (red and blue glad hands)
• Electrical connection secure

Tug test procedure:

1. Connect trailer
2. Set trailer brakes
3. Put tractor in low gear
4. Slowly pull forward
5. Trailer should NOT separate

Cargo Securement

• Cargo distributed evenly
• Proper number of tie-downs (minimum: 1 tie-down per 10 feet of cargo, minimum of 2 total)
• Tie-downs tight (no slack)
• No damaged tie-downs (cuts, fraying, burns)
• Tarps secure (if used)
• Doors latched (if van trailer)

Emergency Equipment

• Fire extinguisher mounted and charged (gauge in green zone)
• 3 reflective triangles in storage box
• Spare fuses (if not circuit breakers)
• First aid kit (recommended, not always required)

Trailer-Specific Items

• Landing gear fully raised and handle secured
• Mud flaps present
• DOT number visible
• License plate secure and visible

Time required for thorough pre-trip: 15-20 minutes

Time to fix violation found during DOT inspection: Hours or days + fines + CSA points

Worth it to do pre-trip properly.

What "Out of Service" Means

Out-of-service order = You cannot drive until violation is fixed.

How it works:

1. Inspector finds critical violation (brake defect, HOS violation, expired medical card)
2. Inspector issues out-of-service order
3. You MUST stop driving immediately
4. Violation must be repaired or corrected
5. Proof of repair may be required
6. Only then can you resume driving

If you continue driving under OOS order:

• Additional fines ($2,000+)
• Criminal charges possible
• License suspension
• Vehicle can be towed/impounded

Common OOS repairs:

• Brake adjustment: Mobile mechanic can fix ($200-$400)
• Tire replacement: Buy tire at truck stop, have it mounted
• Lighting: Replace bulbs (keep spares in truck)
• HOS violation: Take mandatory 10-hour break

From TruckersReport forum:

"Failed first DOT inspection. Got cited for unmounted fire extinguisher and logbook issues. Went out of service for 10 hours to fix HOS violation."

Simple mistakes = hours of downtime.

How to Dispute Inspection Violations

If you believe a violation was issued in error, you can dispute it.

Use the DataQs system:

DataQs = Data Quality System (FMCSA's official dispute process)

How to file:

1. Go to https://dataqs.fmcsa.dot.gov
2. Create account (if first time)
3. Submit challenge within 30 days of inspection
4. Provide evidence (photos, receipts, repair records)
5. Wait for review (can take 45-60 days)

What you can dispute:

• Inspector made factual error (cited wrong regulation)
• Violation was already fixed before inspection
• Measurement was inaccurate (tread depth, brake adjustment)
• Documentation proves compliance

What you CANNOT dispute:

• "Inspector was rude" (not grounds for removing violation)
• "It wasn't that bad" (if it violates regulation, it's a violation)
• "I fixed it right after" (violation still happened)

From TruckersReport forum:

"Use the DataQ system to dispute inspection violations. You have 30 days from inspection date."

Success rate varies. Clear errors get removed. Legitimate violations usually stand.

CSA Points and How They Affect You

Every DOT violation adds CSA points to your record.

CSA = Compliance, Safety, Accountability

How it works:

• Violations categorized into 7 BASIC categories
• Points assigned based on severity
• Points stay on record for 24 months
• More points = higher inspection frequency
• More points = higher insurance rates

The 7 BASIC categories:

1. Unsafe Driving
2. Hours of Service Compliance
3. Driver Fitness
4. Controlled Substances/Alcohol
5. Vehicle Maintenance
6. Crash Indicator
7. Hazardous Materials Compliance

Point severity examples:

• Brake out of adjustment: 4 points
• HOS violation (11-hour rule): 7 points
• Tire violation (tread depth): 8 points if OOS, 2 points if not OOS
• Logbook falsification: 10 points

What happens with high CSA scores:

• More frequent inspections (you become a target)
• Higher insurance premiums
• Intervention from FMCSA
• Potential loss of operating authority
• Harder to get hired (if company driver)

How to check your CSA score:

• SMS (Safety Measurement System) website
• Pre-Employment Screening Program (PSP) report

Tips for Passing DOT Inspections

1. Do Proper Pre-Trip Every Day

Not just "kick the tires."

Actual 15-20 minute walkaround checking everything on the checklist above.

From research:

65% of American commercial carriers fail pre-trip inspections, leading to $8,000-$18,000 in annual penalties per vehicle.

Most violations are things you could have found in pre-trip.

2. Fix Minor Issues Immediately

Don't let small problems become OOS violations.

Burned-out marker light today = citation tomorrow.

Fix it now:

• Keep spare bulbs in truck
• Keep spare glad hand seals
• Keep basic tools for minor repairs

3. Stay Organized

Keep all required documents in one folder:

• License
• Medical card
• Registration
• Insurance
• IFTA credentials
• Last 7 days of logs accessible quickly

Inspector asks for documents. You fumble for 10 minutes.

That's 10 minutes of him staring at your truck finding other things to cite.

You hand him a folder with everything organized.

He's impressed. Inspection goes smoother.

4. Be Polite and Cooperative

Don't argue with inspector.

"That regulation is stupid" or "This is BS" = inspector now motivated to find EVERY violation.

"Yes sir, here's my documentation" = inspector treats you professionally.

From forums:

Attitude matters. Inspectors have discretion on warnings vs citations for minor violations.

5. Know How Your ELD Works

Inspector will ask you to demonstrate ELD functions:

• Show current HOS status
• Show last 7 days of logs
• Explain any edits or annotations

If you can't operate your own ELD, inspector gets suspicious.

6. Don't Try to Hide Violations

Inspector asks about maintenance.

Bad answer: "I don't know, the company handles that."

Good answer: "Last service was 3 weeks ago, here's the receipt."

Trying to hide problems makes it worse.

If inspector finds something you obviously tried to conceal (fresh paint over a crack, duct tape covering a gauge), now he's looking for EVERYTHING.

What Happens After a Clean Inspection

If inspector finds ZERO violations:

• You get a "clean inspection" report
• This HELPS your CSA score (shows compliance)
• Takes 5-10 minutes for inspector to complete paperwork
• You're on your way

Clean inspections improve your safety rating.

Recommendation: Don't avoid inspections. If your truck is compliant, inspections HELP you.

Cost of DOT Violations

Beyond the fines, violations cost you in:

1. CSA Points

• Higher insurance ($2,000-$5,000+ per year increase)
• More frequent inspections (wasted time)

2. Downtime

• Out of service = no revenue
• Average OOS order: 8-12 hours
• At $2.50/mile x 60 mph x 10 hours = $1,500 lost revenue

3. Repair Costs

• Emergency mobile mechanic: 50-100% markup over shop rates
• Tow to shop: $200-$500
• Expedited parts: 2x normal cost

4. Reputation

• Brokers check your inspection history
• Shippers check safety ratings
• Poor inspection record = fewer load opportunities

Annual cost of poor inspection compliance:

Research shows carriers average $8,000-$18,000 per vehicle in penalties when they fail inspections regularly.

Cost of doing pre-trip inspections properly: $0 (just your time)

How FF Dispatch Helps Owner-Operators

DOT violations cost money in fines and downtime, but also in lost opportunities. Brokers and shippers check your inspection record before offering loads. Poor CSA scores mean fewer load options and lower rates.

When you're running tight margins on cheap freight, you can't afford to spend $500 on unexpected brake repairs or lose a day of revenue to an out-of-service order. Better rates give you the cushion to maintain your equipment properly and keep a clean inspection record.

FF Dispatch negotiates rates (averaging $2.40-2.80/mile) that let you invest in preventive maintenance instead of running equipment until it fails during an inspection.

We handle load booking for 6% of gross revenue. No contracts, no hidden fees.

Contact: (302) 608-0609 | gia@dispatchff.com

Bottom Line

DOT inspections come in 3 main levels:

1. Level 1 (North American Standard) - 37-step vehicle + driver inspection, 60-90 min
2. Level 2 (Walk-Around) - Same as Level 1 but no under-vehicle inspection, 30-45 min
3. Level 3 (Driver-Only) - Documents and HOS only, 10-15 min

Most common violations:

Vehicle:

• Brake system issues (leading cause of OOS)
• Tire violations (tread depth, pressure, damage)
• Lighting violations
• Cargo securement issues

Driver:

• Hours of Service violations (32% of all driver violations)
• Expired medical certificate
• ELD malfunctions
• False logbook entries

Pre-trip inspection checklist prevents violations:

• Check all lights, tires, brakes, fluids DAILY
• Keep emergency equipment accessible
• Verify documents current
• Takes 15-20 minutes
• Saves hours of OOS downtime and thousands in fines

Out-of-service criteria:

• 20% or more brakes defective = OOS
• Any steer tire under 4/32" tread = OOS
• HOS violation = OOS until 10-hour break taken
• Expired medical card = OOS until renewed

How to pass inspections:

• Do thorough pre-trip daily
• Fix minor issues immediately
• Keep documents organized
• Be polite and cooperative
• Know how your ELD works

Cost of violations:

• Fines: Varies by violation
• CSA points: Stay on record 24 months
• Insurance increases: $2,000-$5,000+/year
• Downtime: $1,000-$2,000 in lost revenue per OOS order

Clean inspections HELP your CSA score.

Bottom line: 65% of carriers fail inspections. Don't be in that 65%. Spend 20 minutes on pre-trip, avoid hours of OOS and thousands in fines.

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Sources:

• 8 DOT Inspection Levels Explained - Geotab
• Ultimate DOT Inspection Checklist for Owner-Operators - LubeZone
• Level 1 DOT Inspection Ultimate Guide - My Safety Manager
• Level 3 DOT Inspection Guide - My Safety Manager
• DOT Inspection Levels Explained - Lytx
• Out-of-Service Criteria - CVSA
• DOT Out of Service Violations List - My Safety Manager
• 7 Top Causes of DOT Out-of-Service Order - FMCA Filings
• Pre-Trip Inspection Checklist - Epika Fleet
• How to Pass DOT Pre-Trip Inspection - Heavy Vehicle Inspection
• Failed First DOT Inspection - TruckersReport Forum
• How to Dispute Inspection Report - TruckersReport Forum