Use this checklist before any DOT inspection, seasonal fleet review, or when onboarding a new vehicle. Check each item as you verify it. Items flagged in red indicate common CVSA out-of-service violations. At the end, enter your contact information to receive a printable PDF copy and a follow-up from McCarthy's fleet specialists.
⚠ CVSA Level I Criteria Referenced
01
Brake System
0 / 8
▲
Service brakes functional and within adjustment limits
Check pushrod travel and slack adjuster stroke. Automatic slack adjusters should maintain 5/8" to 3/4" stroke.
Parking brake system holds vehicle on grade
Spring brakes must hold without air pressure. Test on an incline with engine off.
Brake drums or rotors within discard specifications
Measure drum diameter against the discard dimension stamped on the drum. No cracks or severe heat checking.
Brake hose and tubing — no leaks, cracks, or chafing
Inspect full length of brake hose and lines. Any audible air leak is an OOS condition.
Low pressure warning device activates at or above 60 PSI
Verify the warning light or buzzer activates before the protection valve cuts in at 45 PSI.
Tractor protection valve operational
Must close automatically when air pressure drops to prevent total brake loss on trailer separation.
Antilock brake system (ABS) warning light clears after self-test
ABS light illuminates at key-on then extinguishes after self-test. A constant light indicates an active fault code.
Automatic brake adjusters maintaining proper stroke
Inspect at every PM. Brake linings must have no oil or grease contamination. Replace contaminated linings immediately.
02
Coupling Devices
0 / 5
▼
Fifth wheel — no excessive wear, properly mounted and latched
Inspect locking mechanism. Kingpin should not have more than 1/2" horizontal movement. Mounting bolts tight.
Pintle hooks — no cracks, deformation, or excessive wear
Inspect latch and safety latch. Applies to straight trucks and converter dollies with pintle-hook connections.
Drawbar/towbar eye and tongue — no cracks or wear beyond limits
Check eye opening for excessive wear. Inspect tongue welds and connection hardware for integrity.
Safety devices (chains/cables) present, secured, and undamaged
Safety chains or cables must be crossed under the tongue and attached to prevent ground contact if disconnected.
Saddle-mounts — all fasteners present and tight
Inspect upper and lower couplers on saddle-mount configurations. No missing or loose fasteners.
03
Exhaust, Fuel & Lighting
0 / 7
▼
Exhaust — no leaks forward of or directly below driver/sleeper compartment
Exhaust leaks forward of the cab are a driver safety hazard and an OOS violation. Check manifold, DPF connections, and flex pipe.
Exhaust unlikely to burn, char, or damage fuel supply or wiring
Inspect routing of exhaust relative to fuel lines, DEF lines, and electrical harnesses for heat exposure risk.
Fuel system — no visible leaks at lines, filters, or tank
Fuel leak is an immediate OOS condition. Check under the vehicle at rest after engine warmup. Fuel tank filler cap must be present and secure.
Fuel tank securely attached — no loose or missing brackets
Inspect fuel tank mounting straps and brackets for corrosion or looseness. Tank must not shift under load.
All required lights and reflectors operational
Headlights, brake lights, turn signals, clearance lights, marker lights, and reflectors. Cracked lenses and misaligned headlights also count as violations.
Reflective conspicuity tape intact on trailer (FMCSA required)
Required on trailers over 10,000 lbs. Peeling, missing, or non-reflective tape is a violation.
Windshield glazing — no disqualifying cracks, discoloration, or obstructions
See 49 CFR 393.60 for exceptions. Cracks in the driver's critical viewing area are an OOS condition. Windshield wipers must be present and operable.
04
Safe Loading
0 / 4
▼
Vehicle parts, load, and dunnage properly secured — no shifting or loss risk
All cargo must be secured per 49 CFR 393. Unsecured load is an OOS violation and a public safety hazard.
Spare tire properly mounted and secured if carried
Unsecured spare tires are a violation and a road hazard. Inspect carrier bracket or under-mount hardware.
Front end structure intact — no damage that affects cargo retention
Inspect front wall, header board, and any front-end protection device for structural damage.
Intermodal container securement devices fully engaged
All twist locks, corner castings, and locking pins must be properly seated and verified before movement.
05
Steering & Suspension
0 / 8
▼
Steering wheel free-play within spec (2" max for power steering)
Excessive play indicates worn steering gear or loose tie rod ends. OOS if play exceeds spec per 49 CFR 393.209.
Steering column — no looseness or binding
U-joint connections and column mounting must be secure. Any binding or looseness in the column is an OOS condition.
Front axle beam and all steering components — no visible cracks or damage
Inspect the front axle beam, steering gear box, pitman arm, power steering components, and ball and socket joints.
Tie rods, drag links, and nuts — no excessive play or looseness
Raise the front axle and check for play. Any looseness in steering linkage is an OOS condition per CVSA standards.
Power steering fluid at proper level — no leaks
Check reservoir with engine warm. Look for staining along rack, gear housing, and hoses under the vehicle.
Spring assembly — no broken or missing leaves, no shifted axle
A cracked or separated leaf spring is an OOS violation. Air bag suspensions: check for deflated bags and abnormal ride height.
Axle positioning parts — torque rods, radius rods, and tracking components secure
Loose or broken torque rods cause axle walk and rapid tire wear. Inspect mounting brackets and bushings for wear or cracking.
Front axle alignment current — within 12 months or manufacturer mileage interval
1/8" toe misalignment on a steer axle consumes a steer tire in under 30,000 miles. Schedule alignment annually at minimum.
06
Frame
0 / 3
▼
Frame members — no cracks, breaks, or severe corrosion
Inspect main rails and crossmembers. Cracked frame members are an OOS condition under 49 CFR 393.201.
Tire and wheel clearance adequate — no contact with frame or body
Check clearance at full steering lock and loaded suspension compression. Rubbing causes rapid tire damage.
Adjustable axle assemblies (sliding subframes) — locking pins fully engaged
All locking pins must be fully seated with no indication of movement. Verify position marking alignment.
07
Tires, Wheels & Rims
0 / 8
▼
Steer-axle tires — tread depth 4/32" minimum at major grooves
CVSA OOS threshold. Measure at two or more locations. No exposed cords, sidewall bulges, or visible damage.
All other tires — tread depth 2/32" minimum, no damage or sidewall defects
Drive and trailer positions. No cuts exposing ply or cord, no bulges, no flat spots. Duals must not contact each other.
Speed-restricted tires not used where speed exceeds their rating
Tires marked with a speed restriction must not be operated above that limit. Verify any speed-restricted tires are appropriate for the route.
Tire inflation within manufacturer cold PSI specification
10% underinflation reduces tread life by 10–15% and increases fuel consumption. Check cold before the first trip of the day.
Lock rings, side rings — no cracked, bent, or sprung components
Applies to multi-piece rim assemblies. Any damage to lock or side rings is an OOS condition due to explosive separation risk.
Wheels and rims — no cracks, breaks, or severe corrosion at bolt holes
Inspect around valve stem holes and bolt hole areas particularly. Cracked disc wheels are an OOS violation.
Fasteners (lug nuts) — all present, not loose, torqued to spec
Missing or loose lug nuts are an OOS violation. Verify torque after any wheel removal. Check for rust streaks indicating movement.
Weld integrity — no visible weld cracks on disc wheels or rims
Inspect welds on disc wheels at the rim flange. Any cracked weld is an OOS condition requiring immediate replacement.
08
Rear Impact Guard & Other
0 / 5
▼
Rear impact guard (ICC bumper) in place and securely attached
Required on trailers per 49 CFR 393.86. Must be proper size and placement. No missing hardware or structural damage.
Motorcoach seats securely fastened to vehicle structure (if applicable)
Applies to motorcoach and bus vehicles only. All passenger seats must be anchored per manufacturer specification.
Wheel end seals — no active oil leaks at hubs or axle ends
Oil contamination on brakes is an OOS violation. Check hub caps and drums for seepage after road operation.
Emergency equipment in cab — triangles, fire extinguisher, first aid
3 reflective triangles or 6 fusees, fire extinguisher (10 BC minimum). Required on all CMVs per 49 CFR 393.95.
Annual inspection certification current and on file (49 CFR Part 396)
Copy of the most recent annual inspection report must be retained at the motor carrier's principal place of business for 14 months.
Your Fleet Readiness Score
Get Your Printable PDF + McCarthy's Review
Enter your information below to receive a branded, print-ready version of this checklist and a follow-up from McCarthy's fleet specialists — who can schedule a complimentary on-site inspection for your fleet.
McCarthy Tire will not share your information. You'll receive the PDF within minutes and a follow-up call from our fleet team within one business day.
Checklist Sent
Your printable PDF is on its way to your inbox. A McCarthy fleet specialist will follow up within one business day to discuss a complimentary fleet inspection for your operation.
Need immediate service or want to talk tires now?
Need immediate service or want to talk tires now?
Failed a check? McCarthy can fix it.
DOT inspections, brake work, alignments, tires, and mechanical — all at 340 Kidder Street or dispatched to your yard.
📞 800-724-3506 · 24/7
If It Rolls, We Can Handle It!
We handle some of the largest fleets in the country. If it rolls, we can handle it! Some of our customers include:
Beverage distributors, bus companies, car dealers, car rental agencies, casinos and resorts, construction equipment, corporate fleets, dry vans, farmers, food delivery, forestry, home builders trucks, hospital vehicles, intermodal, landscapers, logistics, long-haul trucker, medical services, mining companies, municipal and DPW vehicles, pet services, race tracks, quarries, over-the-road trucks, sanitation vehicles, school buses, school districts, service and delivery trucks, telecom companies, third party logistics providers (3PL) trucks, utility companies, waste loaders, and more!
Our Fleet Management Program includes comprehensive account services. National account, government services, commercial credit, or private pay – we can handle them all.