International Truck Systems and Components Inspection Checklist

Comprehensive inspection guide for all major systems and components

Inspection Overview

This comprehensive inspection checklist provides detailed guidance for thoroughly evaluating all major systems and components on International Trucks. Use this checklist during diagnostic procedures, pre-purchase inspections, or when troubleshooting specific issues.

For each system, follow the inspection steps outlined and document any concerns or abnormalities. The checklist is organized by major vehicle systems, with specific inspection points for key components within each system.

Note: Always refer to the specific International Truck model's service manual for model-specific inspection criteria, test specifications, and component locations. This checklist provides general guidance applicable to most International Truck models.

Engine and Related Systems

Perform these inspections to evaluate engine condition, performance, and related systems.

Engine Block and Components

  • Inspect engine block for cracks, leaks, or damage
  • Check cylinder head gasket for signs of leakage
  • Inspect valve cover gaskets for oil seepage
  • Check main bearing cap for proper torque and seating
  • Inspect oil pan for damage and secure mounting
  • Check for excessive blowby from crankcase ventilation
  • Inspect timing cover for oil leaks or damage
  • Check engine mounts for wear, cracks, or separation

Cooling System Components

  • Inspect radiator for leaks, damage, or restrictions
  • Check coolant hoses for cracks, softness, or bulging
  • Inspect water pump for leakage or bearing play
  • Check thermostat housing for cracks or leaks
  • Inspect fan clutch for proper engagement and disengagement
  • Check coolant recovery bottle and cap condition
  • Inspect radiator cap for proper pressure rating
  • Check cooling system pressure with pressure tester

Fuel System Components

  • Inspect fuel tank for damage, leaks, or secure mounting
  • Check fuel lines for leaks, kinks, or deterioration
  • Inspect primary and secondary fuel filters for restriction
  • Check fuel pump for proper pressure and flow
  • Inspect fuel injectors for proper spray pattern
  • Check high-pressure injection lines for leaks
  • Inspect fuel rail pressure sensor function
  • Check common rail system for proper pressure

Air Intake System

  • Inspect air filter housing for cracks or loose mounting
  • Check air filter element condition and restriction
  • Inspect intake ducting for cracks, holes, or collapsed sections
  • Check turbocharger for shaft play or oil leakage
  • Inspect compressor and turbine wheels for damage
  • Check intercooler for leaks or damaged fins
  • Inspect intake manifold for cracks or gasket leaks
  • Check air intake heater operation (if equipped)

Exhaust and Aftertreatment

  • Inspect exhaust manifold for cracks or leaks
  • Check exhaust piping for holes or secure mounting
  • Inspect DPF for excessive soot accumulation
  • Check SCR catalyst for physical damage
  • Inspect DEF tank for contamination or damage
  • Check DEF pump, lines, and injector for leaks
  • Inspect exhaust gas recirculation (EGR) valve
  • Check exhaust brake function (if equipped)

Lubrication System

  • Check oil pump for proper pressure at idle and high RPM
  • Inspect oil cooler for leaks or restrictions
  • Check oil filter mounting for leaks or looseness
  • Inspect oil pressure sensor and gauge operation
  • Check oil level and condition
  • Inspect oil lines for leaks or deterioration
  • Check for metal particles in oil or on magnetic drain plug
  • Inspect oil bypass valve operation

Engine Control System

  • Check ECM for stored fault codes
  • Inspect ECM connectors for corrosion or looseness
  • Check throttle position sensor calibration
  • Inspect crankshaft and camshaft position sensors
  • Check coolant temperature sensor operation
  • Inspect engine oil pressure sensor
  • Check intake air temperature sensor
  • Inspect all engine wiring harness connections

Drivetrain Components

Perform these inspections to evaluate transmission, driveline, and axle components.

Transmission Inspection

  • Check transmission case for cracks or leaks
  • Inspect input shaft seal for leakage
  • Check output shaft seal for leakage
  • Inspect transmission mounts for wear or damage
  • Check fluid level and condition
  • Inspect shift linkage for proper adjustment
  • Check clutch release mechanism (manual transmission)
  • Inspect transmission cooler lines for leaks

Clutch System (Manual)

  • Check clutch pedal free play
  • Inspect clutch disc wear
  • Check pressure plate for heat damage or cracks
  • Inspect flywheel surface condition
  • Check release bearing for smooth operation
  • Inspect clutch fork for wear or damage
  • Check clutch hydraulic system for leaks (if equipped)
  • Inspect clutch brake function

Automatic Transmission

  • Check for correct shift timing and quality
  • Inspect torque converter lockup operation
  • Check transmission for slippage
  • Inspect valve body operation
  • Check solenoid function via scanner
  • Inspect transmission oil cooler for leaks
  • Check transmission range selector operation
  • Inspect electronic controls and harness connections

Driveline Components

  • Check driveshaft for runout or balance issues
  • Inspect U-joints for wear or looseness
  • Check slip yoke for proper movement
  • Inspect center support bearing (if equipped)
  • Check driveline angles for proper specification
  • Inspect yoke splines for wear
  • Check driveshaft phasing
  • Inspect carrier bearing for play or noise

Differential and Axles

  • Inspect differential housing for cracks or leaks
  • Check ring and pinion gear pattern
  • Inspect axle shafts for wear or damage
  • Check differential carrier mounting
  • Inspect wheel bearings for play or roughness
  • Check wheel seals for leakage
  • Inspect axle breathers for proper operation
  • Check interaxle differential lock function (if equipped)

Power Take-Off (PTO)

  • Inspect PTO housing for cracks or leaks
  • Check PTO engagement and disengagement
  • Inspect PTO output shaft for wear
  • Check PTO bearings for noise or roughness
  • Inspect PTO gear teeth condition
  • Check hydraulic PTO pump function (if equipped)
  • Inspect PTO control system
  • Check PTO speed settings and operation

Electrical System

Perform these inspections to evaluate electrical components and circuits.

Battery and Charging

  • Check battery case condition and security
  • Inspect battery terminals for corrosion
  • Check battery voltage (12.6V+ fully charged)
  • Perform load test on batteries
  • Inspect alternator mounting and belt tension
  • Check alternator output voltage (13.8-14.5V)
  • Inspect charging circuit wiring
  • Check battery box drain for blockage

Starting System

  • Inspect starter mounting and security
  • Check starter solenoid operation
  • Measure starter current draw during cranking
  • Inspect starter drive gear engagement
  • Check starting circuit wiring and connections
  • Inspect starting circuit relay
  • Check ignition switch operation
  • Measure voltage drop across starter circuit

Lighting System

  • Check headlight operation (high and low beam)
  • Inspect turn signal operation and flasher rate
  • Check brake light operation and brightness
  • Inspect clearance and marker lights
  • Check dash lights and instrument illumination
  • Inspect interior dome and reading lights
  • Check fog light operation (if equipped)
  • Inspect all light housings for cracks or moisture

Wiring and Connections

  • Inspect main wiring harness for chafing or damage
  • Check all visible connectors for corrosion
  • Inspect fuse panel for burnt or loose connections
  • Check ground strap connections
  • Inspect junction blocks for corrosion or overheating
  • Check chassis wiring for secure routing
  • Inspect trailer connection wiring
  • Check battery cables for fraying or corrosion

Instruments and Controls

  • Check all gauges for proper operation
  • Inspect warning light function
  • Check instrument cluster for illumination issues
  • Inspect switches for proper operation
  • Check electronic instrument cluster pixels
  • Inspect multifunction stalk controls
  • Check horn operation
  • Test windshield wiper and washer operation

Electronic Control Modules

  • Check ECM for diagnostic trouble codes
  • Inspect TCM (transmission control module)
  • Check ABS module for codes
  • Inspect body control module
  • Check instrument cluster module
  • Inspect electronic control module mounting
  • Check module power and ground connections
  • Inspect module software versions

Connect diagnostic equipment to perform comprehensive electronic system checks and document all fault codes.

Chassis and Suspension

Perform these inspections to evaluate frame, suspension, and steering components.

Frame and Crossmembers

  • Inspect frame rails for cracks or bends
  • Check crossmembers for damage or loose fasteners
  • Inspect frame for signs of previous repair
  • Check frame rail for corrosion or rust-through
  • Inspect body mount brackets
  • Check fifth wheel mounting to frame
  • Inspect bumper mounting
  • Check fuel tank mounting brackets

Leaf Spring Suspension

  • Inspect leaf springs for cracks or broken leaves
  • Check spring eye bushings for wear
  • Inspect shackles and pins for wear
  • Check spring center bolt alignment
  • Inspect spring hangers for cracks
  • Check U-bolts for proper torque
  • Inspect spring clips or clamps
  • Check axle alignment

Air Suspension System

  • Inspect air bags for cracks or leaks
  • Check air suspension height control valves
  • Inspect air lines for chafing or leaks
  • Check suspension air tank for leaks
  • Inspect shock absorbers for leaks or damage
  • Check suspension leveling and height
  • Inspect air suspension dump valve operation
  • Check transverse rods and bushings

Steering System

  • Check steering wheel for free play
  • Inspect steering shaft and U-joints
  • Check steering gear box mounting
  • Inspect power steering pump for leaks
  • Check steering linkage for wear or play
  • Inspect tie rod ends for looseness
  • Check drag link for wear
  • Inspect steering knuckles and kingpins

Wheel Alignment

  • Check for uneven tire wear indicating alignment issues
  • Inspect caster angle
  • Check camber adjustment
  • Inspect toe setting
  • Check axle alignment
  • Inspect thrust angle
  • Check for bent or damaged components affecting alignment
  • Inspect steering wheel position at straight ahead

Fifth Wheel and Coupling

  • Inspect fifth wheel for cracks or damage
  • Check fifth wheel jaw locking mechanism
  • Inspect fifth wheel mounting bolts
  • Check fifth wheel top plate for wear
  • Inspect slider mechanism and locks (if equipped)
  • Check release handle and safety latch
  • Inspect kingpin locking test
  • Check mounting height

Always perform a tug test to verify proper fifth wheel coupling before operation.

Brake System

Perform these inspections to evaluate air brake system components and function.

Air Compressor and Governor

  • Check air compressor mounting and drive
  • Inspect compressor unloader mechanism
  • Check governor cut-in pressure (typically 100 psi)
  • Inspect governor cut-out pressure (typically 125 psi)
  • Check air compressor for excessive oil passage
  • Inspect air compressor inlet for restrictions
  • Check compressor discharge line
  • Inspect compressor cooling

Air Tanks and Lines

  • Check air tanks for secure mounting
  • Inspect tank drain valves for function
  • Check for moisture or contamination in tanks
  • Inspect air lines for chafing or kinks
  • Check fittings for leaks
  • Inspect one-way check valves
  • Check pressure protection valves
  • Inspect air tank safety valve

Air Dryer System

  • Inspect air dryer mounting
  • Check purge valve operation
  • Inspect heater function (if equipped)
  • Check desiccant condition (color indicator)
  • Inspect air dryer inlet and outlet fittings
  • Check for excessive purge cycle frequency
  • Inspect governor to air dryer line
  • Check coalescent filter (if equipped)

Foundation Brakes

  • Measure brake lining thickness
  • Inspect brake drums for scoring or cracking
  • Check brake shoe return springs
  • Inspect S-cam bushings for wear
  • Check brake spider mounting
  • Inspect brake adjuster function
  • Check brake chamber mounting and condition
  • Inspect dust shields

Air Disc Brakes

  • Check disc brake pad thickness
  • Inspect rotor for cracks or scoring
  • Check caliper slide pin movement
  • Inspect caliper piston and boot
  • Check caliper mounting
  • Inspect brake chamber and push rod
  • Check for signs of overheating
  • Inspect adjuster mechanism

Brake Valves and Controls

  • Check foot valve operation
  • Inspect trailer control valve
  • Test spring brake control valve
  • Check quick release valves
  • Inspect relay valves
  • Check parking brake function
  • Inspect limiting and proportioning valves
  • Test anti-compound valve

ABS System

  • Check for ABS warning light activation
  • Inspect ABS wheel speed sensors
  • Check ABS modulator valves
  • Inspect ABS ECU mounting and connections
  • Check ABS wiring harness
  • Inspect sensor exciter rings
  • Check for stored ABS fault codes
  • Test ABS self-diagnostic function

Cab and Body Components

Perform these inspections to evaluate cab condition, controls, and body components.

Cab Structure

  • Inspect cab for structural damage
  • Check cab mounts and isolators
  • Inspect cab tilt mechanism (if equipped)
  • Check doors for proper alignment and seal
  • Inspect windshield and other glass for cracks
  • Check door hinges and latches
  • Inspect steps and grab handles
  • Check fenders and hood condition

HVAC System

  • Check heater function and temperature
  • Inspect A/C cooling performance
  • Check for proper air flow from all vents
  • Inspect blower motor operation
  • Check HVAC controls
  • Inspect cabin air filter
  • Check A/C compressor and clutch
  • Inspect refrigerant lines for leaks

Driver Controls

  • Check steering wheel adjustment
  • Inspect pedal position and condition
  • Check seat adjustments and mechanisms
  • Inspect mirrors and adjustments
  • Check instrument visibility
  • Inspect control switches for function
  • Check accessory controls
  • Inspect control knob condition

Interior Components

  • Check seat upholstery condition
  • Inspect seat belts for wear or damage
  • Check floor covering condition
  • Inspect door panels and trim
  • Check headliner condition
  • Inspect storage compartments
  • Check sleeper berth components (if equipped)
  • Inspect interior lighting

Exterior Body

  • Check paint condition
  • Inspect for body rust or corrosion
  • Check body panel alignment
  • Inspect mud flaps
  • Check bumper condition
  • Inspect grille for damage
  • Check hood latches and supports
  • Inspect exterior trim and moldings

Windows and Mirrors

  • Check power window operation
  • Inspect window regulators
  • Check window seals for leaks
  • Inspect mirror glass for defects
  • Check mirror heaters (if equipped)
  • Inspect mirror adjustment motors
  • Check windshield washer nozzles
  • Inspect wiper arms and blades

Safety and Auxiliary Systems

Perform these inspections to evaluate safety equipment and auxiliary systems.

Safety Equipment

  • Check fire extinguisher charge and mounting
  • Inspect reflective triangles or flares
  • Check first aid kit contents and accessibility
  • Inspect seat belt condition and function
  • Check horn operation
  • Inspect safety decals and placards
  • Check backup alarm function
  • Inspect emergency equipment access

Advanced Safety Systems

  • Check collision mitigation system (if equipped)
  • Inspect lane departure warning system
  • Test adaptive cruise control
  • Check blind spot detection system
  • Inspect rollover stability control
  • Check driver alertness monitoring
  • Inspect camera systems
  • Test obstacle detection sensors

Hydraulic Systems

  • Check hydraulic fluid level and condition
  • Inspect hydraulic pump function
  • Check hydraulic cylinders for leaks
  • Inspect hydraulic hoses and fittings
  • Check hydraulic valve operation
  • Inspect hydraulic reservoir
  • Check hydraulic filter condition
  • Test hydraulic pressure relief function

Auxiliary Power Systems

  • Check APU (auxiliary power unit) operation
  • Inspect generator system
  • Check inverter function
  • Inspect shore power connections
  • Check hotel load power system
  • Inspect battery isolation system
  • Check auxiliary heating system
  • Inspect refrigeration unit (if equipped)

Communication Systems

  • Check CB radio operation
  • Inspect satellite communication system
  • Check GPS navigation system
  • Inspect telematics unit
  • Check antenna mounts and cables
  • Inspect in-cab communication devices
  • Check electronic logging device (ELD)
  • Inspect fleet management system

Body Auxiliary Systems

  • Check lift gate operation (if equipped)
  • Inspect roll-up door function
  • Check cargo securement systems
  • Inspect load control system
  • Check liftable axle controls (if equipped)
  • Inspect tarping system (if equipped)
  • Check loading ramps or equipment
  • Inspect specialized body components
Use Checklist Online

© 2025 International Truck Systems and Components Inspection Checklist | Developed by FleetRabbit | Contact us at support@fleetrabbit.com for customized inspection solutions.