Key Inspection Preparation Procedures
Follow these procedures to thoroughly prepare your vehicle for DOT annual inspection, focusing on common failure points and inspection priorities.
Brake Adjustment Procedure
- Position vehicle on level surface and chock wheels
- Release spring brakes and verify air system is at operating pressure
- Measure pushrod travel at 90-100 psi application pressure
- Compare measurements to specification chart for chamber type/size
- Adjust brakes that exceed 80% of adjustment limit
- Verify adjustment holds after several brake applications
- Document all measurements and adjustments performed
Lighting System Check
- Clean all light lenses thoroughly before inspection
- Check all lights with a partner or using reflection method
- Verify proper function of high/low beams, turn signals, brake lights
- Inspect all marker lights and reflectors for proper operation
- Check wiring harnesses for secure connections and chafing
- Replace any cracked or fogged lenses
- Verify all lights are securely mounted and properly aimed
Air Brake System Test
- Build system to governor cutout (typically 120-140 psi)
- Shut off engine and apply service brake firmly
- Monitor air gauge for one minute (loss should not exceed 3-4 psi)
- Start engine and rebuild pressure to governor cutout
- Fan brakes to reduce pressure and verify low air warning at 55-75 psi
- Continue reducing pressure to verify spring brake activation (20-40 psi)
- Check air dryer function and drain all air tanks
Suspension & Frame Inspection
- Inspect frame rails thoroughly using flashlight
- Check all spring leaves for cracks or shifts
- Verify all U-bolts are tight and intact
- Inspect shock absorbers for leaks and secure mounting
- Check torque arms and bushings for excessive wear
- Inspect air suspension components for proper inflation and leaks
- Look for any illegal welds or repairs on frame components
Top 5 FAQs
- What is DOT Annual Inspection? Mandatory yearly inspection under 49 CFR 396.17 for all commercial vehicles in interstate commerce.
- Who performs this inspection? Certified DOT inspectors or qualified technicians approved by your fleet or repair facility.
- How can I prepare? Use this checklist covering brakes, suspension, lights, frame, emergency equipment, and documentation.
- Is this checklist compliant? Yes, it aligns with Appendix G of FMCSA requirements for commercial vehicle inspections.
- Can this be completed digitally? Yes, through the FleetRabbit platform with full tracking, signature capture, and automated scheduling.