Annual DOT Level-1 Truck Inspection Checklist

Complete 37-step North American Standard Inspection procedure for commercial vehicles. This comprehensive inspection covers both driver qualifications and vehicle mechanical fitness.

✅ What is a Level-1 Inspection?

The Level-1 inspection is the most comprehensive DOT inspection. It includes examination of driver's license, medical certificate, alcohol and drugs, hours of service, seat belt, vehicle inspection report, brake system, coupling devices, exhaust system, frame, fuel system, lighting devices, safe loading, steering mechanism, suspension, tires, van and open-top trailer bodies, wheels/rims/hubs, windshield wipers, and emergency exits on buses.

⛔ Critical Out-of-Service Criteria

Any violation of the North American Standard Out-of-Service Criteria must be corrected before the vehicle can be operated. Vehicles passing with no OOS violations receive a CVSA decal valid for three months.

Pre-Inspection Requirements

  • Inspector must be certified for Level-1 inspections.
  • Have current CVSA out-of-service criteria handbook.
  • Inspection tools: tape measure, tire depth gauge, flashlight, creeper.
  • Inspection forms and CVSA decals if applicable.
  • Camera for documenting violations.
  • Park vehicle on level ground with parking brake set.
  • Chock wheels for safety during brake checks.
  • Allow 30-45 minutes for complete inspection.

Part 1: Driver Documentation (Steps 1-7)

  • CDL: Verify valid Commercial Driver's License with proper class and endorsements for vehicle type.
  • Medical Certificate: Check expiration date and verify driver meets physical qualifications.
  • Skill Performance Evaluation: If applicable, verify SPE certificate for drivers with physical impairments.
  • Hours of Service: Review logs for past 7 days (8 days if using 8-day cycle).
  • ELD Compliance: Verify Electronic Logging Device is functioning and data can be transferred.
  • Vehicle Inspection Report: Review previous DVIR and verify defects were corrected.
  • Alcohol/Drugs: Check for presence or use (0.04% BAC limit for CDL holders).

Part 2: Vehicle Documentation (Steps 8-10)

  • Registration: Current and valid for vehicle and state of operation.
  • Insurance: Proof of minimum liability coverage (MCS-90 endorsement).
  • Annual Inspection: Valid inspection sticker or report within 12 months.

Part 3: Brake System Inspection (Steps 11-16)

  • Brake Adjustment Check: Measure pushrod travel with brakes fully applied at 80-90 psi.
  • Air Loss Test: With brakes released, loss should not exceed 3 psi/min (single) or 4 psi/min (combination).
  • Low Pressure Warning: Must activate before air pressure drops below 55 psi.
  • Tractor Protection Valve: Must close automatically between 20-45 psi.
  • Spring Brakes: Must apply automatically when air pressure drops below manufacturer's specification.
  • Service Brakes: Must stop vehicle within prescribed distance at 20 mph.

Brake Adjustment Limits

Brake Type Size Maximum Adjustment
Cam (S-Cam) All sizes 2 inches
Wedge Brakes All sizes 2 inches
Disc Brakes All types 0.75 inches

Part 4: Coupling Devices (Steps 17-18)

  • Fifth Wheel: No space between upper and lower fifth wheel, properly lubricated, locking mechanism secure.
  • Pintle Hooks: Properly closed and locked, safety chains crossed and secured.
  • Drawbar/Towbar: All components present, no cracks or damage.
  • Safety Devices: Safety chains/cables adequate size and properly attached.

Part 5: Exhaust System (Step 19)

  • No leaks forward of or directly below driver/sleeper compartment.
  • System securely mounted with all clamps and hangers intact.
  • No contact with fuel system, wiring, or air lines.
  • Diesel Particulate Filter (DPF) present and intact if required.
  • No temporary repairs with wrap or tape.

Part 6: Frame (Step 20)

  • No cracks in frame rails longer than 1.5 inches.
  • No cracks extending through top or bottom rail flange.
  • All fasteners present and tight.
  • No prohibited frame repairs or holes.
  • Cab and body mounts secure.

Part 7: Fuel System (Step 21)

  • No fuel leaks at tank, lines, or connections.
  • Tank(s) securely mounted with proper straps/brackets.
  • Fuel cap present, proper type, and secure.
  • No contact between fuel lines and exhaust system.
  • Visible fuel in tank (not running on fumes).

Part 8: Lighting Devices (Steps 22-24)

  • Required Lights Must Function:
  • Headlights - both high and low beam
  • Tail lights - all required positions
  • Stop lights - all positions, activated by service brake
  • Turn signals - front and rear, proper color
  • Clearance lights - front amber, rear red
  • Side marker lights - amber front, red rear
  • Identification lights - three red rear for vehicles ≥80" wide
  • Reflectors clean and proper color/placement
  • Conspicuity tape if required (manufactured after 1993)

Part 9: Steering (Steps 25-26)

  • Steering Wheel Free Play Limits:
  • Manual steering: 2 inches maximum
  • Power steering: 4.5 inches maximum (measured at rim)
  • No looseness in steering column or box mounting
  • Power steering fluid adequate, no major leaks
  • No welded repairs to steering components
  • Ball joints and tie rod ends secure

Part 10: Suspension (Steps 27-28)

  • Leaf Springs: No broken main leaf, no more than 25% of leaves broken
  • Coil Springs: No broken or missing springs
  • Air Bags: Properly inflated, no leaks or damage
  • Shock Absorbers: Secure mounting, no severe leaks
  • U-bolts tight and secure
  • No shifted or missing leaves
  • Torque/radius rods secure

Part 11: Tires (Steps 29-31)

  • Minimum Tread Depth:
  • Steer axle: 4/32 inch
  • All other positions: 2/32 inch
  • No exposed fabric through tread or sidewall
  • No cuts exposing steel belt or ply
  • No bulges or knots indicating separation
  • Proper inflation (no flat tires)
  • No regrooved or recapped tires on steer axle
  • Tires match in size on same axle (dual tires)
  • No mixing of radial and bias ply on same axle

Part 12: Wheels & Rims (Steps 32-33)

  • No missing, broken, or loose wheel fasteners
  • No cracks in wheels extending to bolt holes or edge
  • No welded repairs to aluminum wheels
  • Lock rings and side rings properly seated (multi-piece rims)
  • No excessive rust or corrosion
  • Proper wheel/rim match to tire size

Part 13: Windshield & Wipers (Step 34)

  • No discoloration or damage in driver's swept area exceeding 1/4 inch
  • No cracks over 3 inches in critical area
  • Wipers operational and effective
  • Washer fluid reservoir filled
  • No unauthorized stickers in swept area

Part 14: Emergency Equipment (Step 35)

  • Fire Extinguisher: Properly charged, rated B:C or ABC, securely mounted
  • Warning Devices: Three bidirectional reflective triangles or approved alternatives
  • Spare Fuses: If vehicle uses fuses (not required for circuit breakers)
  • Equipment readily accessible to driver

Part 15: Safe Loading (Steps 36-37)

  • Cargo properly distributed and secured
  • No loose articles that could fall from vehicle
  • Adequate number of tie-downs (minimum 1 per 10 feet of cargo)
  • Working Load Limit (WLL) adequate for cargo weight
  • Blocking and bracing secure
  • Tailgate, doors, tarps properly secured
  • No overwidth/overheight without proper permits
  • Hazmat properly placarded and documented

Post-Inspection Procedures

  • Complete inspection report with all findings.
  • If passed: Issue CVSA decal (valid 3 months).
  • If failed: Issue out-of-service order for critical violations.
  • Provide driver/carrier with copy of inspection report.
  • Enter inspection data into state/federal database.
  • Driver/carrier must correct violations before operating.
  • Re-inspection required for OOS violations.
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