DOT Level 1 Inspection Checklist (Free Printable)
A Level 1 North American Standard Inspection is the full 37-step roadside inspection: driver credentials and hours, then a walk-around and under-vehicle check of every major system. It is also the best template for the annual periodic inspection every commercial vehicle must pass under 49 CFR 396.17 (minimum standards in Appendix A to Part 396). Use this checklist before a trip, before the annual, or as a monthly self-audit — the items are the ones inspectors write up most. Free printable Word version below — just tell us where to send it.
⬇ Download the inspection checklist (Word)
Driver side of the inspection
- Driver licence / CDL: correct class and endorsements for the vehicle and cargo; not expired or suspended.
- Medical Examiner's Certificate (or state record for CDL holders), current; any waiver or Skill Performance Evaluation certificate on hand.
- Hours-of-service records: ELD in working order with the instruction sheet, blank paper logs for malfunctions, and the previous seven days available; exemptions documented if claimed.
- Driver Vehicle Inspection Report from the prior trip if a defect was noted, with the repair certification.
- Seat belt in use; no signs of alcohol or drug impairment; no hand-held phone use.
- Shipping papers (bill of lading) and, for hazmat, placarding, papers and emergency-response information within reach.
- Proof of insurance and registration (cab card / IRP), IFTA decals and licence copy, UCR receipt, annual inspection sticker or report in the vehicle.
Brake system (the leading out-of-service category)
- Air pressure builds to governor cut-out; low-air warning activates around 55–75 psi; loss rate within limits with brakes applied.
- Brake adjustment within limits on every axle (measure pushrod stroke); automatic slack adjusters functioning — an out-of-adjustment automatic slack adjuster signals a defect to repair, not "just adjust it".
- No audible air leaks; hoses and tubing not chafed, cracked or rubbing; glad-hands sealing.
- Brake drums/rotors, linings and chambers: no cracks, contamination, missing or loose parts; lining thickness above minimum.
- Parking brake holds; tractor protection valve and trailer supply operate correctly.
- ABS malfunction lamp cycles on then off at start-up (tractor and trailer).
Lighting, electrical and reflective devices
- Headlamps (high/low), tail, stop, turn, hazard, clearance, identification and marker lamps all working; correct colours.
- Reflectors and retroreflective tape present and not obscured.
- License plate lamp works; wiring not exposed, chafed or dangling.
Tires, wheels, hubs and suspension
- Tread depth: steer tires at least 4/32" in a major groove; all others at least 2/32"; no exposed cord, bulges, cuts to the ply, or regrooved tires on the steer axle (unless permitted).
- Inflation within spec; no flat or audibly leaking tires; no tire contacting another tire or vehicle part.
- Wheels and rims: no cracks, bent flanges, missing or loose lug nuts, elongated bolt holes, or rust streaks indicating movement.
- Hubs: no leaking seals; oil level visible in sight-glass hubs.
- Suspension: no cracked or missing leaves, broken hangers, loose U-bolts, leaking or deflated air bags, or damaged torque rods.
Steering, frame, coupling, exhaust, fuel and cab
- Steering wheel free play within limits for the wheel diameter; no loose or missing steering components; power-steering system not leaking.
- Frame and cross-members: no cracks, sagging or loose fasteners; no items bolted through the frame flange improperly.
- Fifth wheel and kingpin: locked, no excessive movement, mounting secure; pintle hooks and safety chains where used.
- Exhaust: no leaks forward of or under the cab, not contacting wiring or fuel lines, discharging where required.
- Fuel system: tank secure, cap present, no leaks anywhere.
- Windshield: no cracks or discolouration in the swept area beyond the allowance; wipers and washers work; horn works; mirrors intact.
- Emergency equipment: charged fire extinguisher secured and accessible, three warning triangles (or equivalent), spare fuses if the vehicle needs them.
Cargo securement and trailer
- Working-load limit of tie-downs meets at least half the cargo weight in aggregate; correct number of tie-downs for the article length and weight.
- Straps, chains and binders not cut, knotted or damaged; edge protection where needed; no shifting cargo.
- Van and open-top trailer bodies: doors latch, no holes or loose panels; landing gear and cross-members secure.
Annual (periodic) inspection specifics — 49 CFR 396.17 / Appendix A
- Every CMV inspected at least once every 12 months by a qualified inspector (49 CFR 396.19 qualifications; keep the inspector's evidence of qualification on file).
- Inspection report retained for 14 months; a copy or a sticker/decal on the vehicle showing the date and where the report can be obtained.
- Any Appendix A defect corrected before the vehicle is returned to service; keep the repair invoice with the report.
- Trailers and converter dollies are inspected too — the most commonly missed annuals in small fleets.
⚠️ What the CVSA decal actually means: passing a Level 1 with no critical violations can earn a CVSA decal valid for three months. It does not substitute for the annual inspection unless the roadside inspection covered all Appendix A items and the report is retained — treat the annual as its own event.
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Start free — no card requiredGeneral guidance for motor carriers, not legal advice. FMCSA rules, fees and state procedures change — verify current requirements with FMCSA (fmcsa.dot.gov) and your state agencies before relying on any item here. FleetClear is not affiliated with the FMCSA or any government agency.