Minimum Periodic Inspection Checklist (49 CFR 396-A)

Complete guide for conducting annual vehicle inspections in accordance with federal requirements. Every commercial motor vehicle must be inspected at least once every 12 months.

📋 What is 49 CFR Part 396 Appendix A?

Appendix A lists the minimum periodic inspection standards for commercial motor vehicles. It specifies what components must be inspected annually to ensure vehicles are maintained in safe operating condition. This inspection must be performed by a qualified inspector.

§ 396.17 Periodic inspection

Every commercial motor vehicle shall be inspected as required by this section. The inspection shall include, at a minimum, the parts and accessories set forth in Appendix A. Motor carriers must retain the original or a copy of the periodic inspection report for 14 months from the date of the report.

Pre-Inspection Preparation

  • Verify inspector qualifications meet § 396.19 requirements.
  • Gather vehicle information: VIN, license, unit number, mileage.
  • Review previous inspection report for recurring issues.
  • Ensure vehicle is clean for proper inspection.
  • Have vehicle on level ground with parking brake set.
  • Gather inspection tools: flashlight, tire gauge, measuring tools.
  • Allow adequate time (typically 1-2 hours per vehicle).

Brake System Inspection

  • Service brakes: Check pedal reserve, brake balance, and stopping ability.
  • Parking brake: Must hold vehicle on specified grade.
  • Brake drums/rotors: Check for cracks, scoring, or thickness.
  • Brake hoses: No leaks, cracks, chafing, or restrictions.
  • Brake tubing: Properly secured, no damage or corrosion.
  • Low pressure warning: Must activate before 55 psi (air brakes).
  • Tractor protection valve: Must operate between 20-45 psi.
  • Air compressor: Proper build-up time and governor operation.
  • Electric brakes: If equipped, check wiring and magnets.
  • Hydraulic brakes: Check master cylinder, wheel cylinders, fluid level.
  • Vacuum brakes: If equipped, check reserve capacity.

Coupling Devices

  • Fifth wheels: No excessive wear, cracks, or missing parts.
  • Locking mechanism: Positive lock around kingpin.
  • Mounting: All bolts tight, no cracks in frame.
  • Pintle hooks: Latch securely closes and locks.
  • Drawbar: No cracks, bends, or missing parts.
  • Safety chains/cables: Proper size and attachment.
  • Saddle mounts: If used, properly secured.

Exhaust System

  • Check entire system from engine to tailpipe.
  • No leaks that would cause fumes to enter cab.
  • System securely mounted with proper clearances.
  • No contact with fuel lines, brake lines, or wiring.
  • Muffler present and functioning.
  • No temporary repairs with wrap or patches.

Fuel System

  • Tank(s) securely mounted with proper straps.
  • No leaks from tank, lines, or connections.
  • Fuel cap seals properly.
  • Lines protected from damage and heat.
  • No contact between fuel and exhaust systems.

Lighting Devices and Reflectors

  • Headlamps: Both high and low beams functioning.
  • Tail lamps: Required number working.
  • Stop lamps: All functioning when brakes applied.
  • Turn signals: Front and rear operational.
  • Clearance/marker lamps: Required colors and positions.
  • Identification lamps: Three red rear if ≥80" wide.
  • Side marker lamps: Amber front, red rear.
  • Reflectors: Clean and proper placement.
  • Conspicuity markings: If required (vehicles after 1993).

Safe Loading

  • Load properly distributed and secured.
  • No overloading of vehicle GVWR or axle ratings.
  • Cargo securing devices adequate for load.
  • No damaged or defective securing devices.
  • Proper blocking and bracing where required.

Steering Mechanism

  • Steering wheel free play within limits.
  • No excessive wear in steering linkage.
  • Front wheels properly aligned.
  • Power steering fluid level adequate.
  • No binding or jamming in steering.
  • All components properly secured.

Suspension

  • No broken or missing leaf springs.
  • No cracked or broken coil springs.
  • No leaking shock absorbers.
  • Air bags properly inflated (if equipped).
  • All mounting bolts and bushings secure.
  • Axles secure and properly aligned.

Frame

  • No cracks, breaks, or holes in frame members.
  • No loose or missing fasteners.
  • All cross members secure.
  • No improper welded repairs.
  • Body and cab mounts secure.

Tires

  • Tread depth minimums:
  • Front/steer axle: 4/32 inch
  • All other tires: 2/32 inch
  • Measure at major tread groove.
  • No fabric showing through tread or sidewall.
  • No cuts exposing ply or belt material.
  • No bulges or knots indicating separation.
  • Proper size and load rating for vehicle.
  • Tires on same axle must match in size.
  • No regrooved or recapped tires on front axle.

Wheels and Rims

  • No cracks extending from bolt holes.
  • All lug nuts present and tight.
  • No cracks in welds (welded wheels).
  • Proper mounting of dual wheels.
  • No excessive corrosion or damage.
  • Lock rings properly seated (if used).

Windshield and Wipers

  • Windshield free of cracks in driver's view area.
  • No discoloration affecting visibility.
  • Wipers operate smoothly through full range.
  • Wiper blades in good condition.
  • Washer system operational.

Additional Required Items

  • Rear vision mirrors: Properly mounted and adjusted.
  • Horn: Audible from 200 feet.
  • Speedometer: Functioning properly.
  • Exhaust emission controls: If required, properly functioning.
  • Cab and body: No sharp edges or protrusions.

Documentation Requirements

  • Complete inspection report with all required information.
  • List all defects found with specific descriptions.
  • Inspector must sign and date the report.
  • Provide copy to motor carrier.
  • Motor carrier must retain for 14 months.
  • Affix inspection sticker/decal if vehicle passes.
  • Document corrective action for any defects found.

Inspection Report Requirements

The inspection report must contain:

Required Information Details
Vehicle Identification Company name, address, USDOT number
Vehicle Information Make, model, year, VIN, unit number
Inspector Information Name, signature, qualification credentials
Inspection Date Month, day, and year of inspection
Components Inspected All items from Appendix A
Defects Found Specific description of each defect
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