Annual DOT Inspection Template: A Manager’s Guide

Last Updated: February 2, 2026By

To remain compliant with 49 CFR §396.17, every Class 8 vehicle must undergo a periodic inspection at least once every 12 months. While many managers buy pre-printed pads, creating a custom, comprehensive digital or physical template ensures your shop technicians are looking at the specific high-wear areas of your unique fleet.

Below is a professional, template designed for a medium-sized fleet.

Annual Vehicle Inspection Report (AVIR)

In Compliance with 49 CFR §396.17 through §396.23

SECTION 1: VEHICLE & CARRIER IDENTIFICATION

  • Inspection Date: ___________________

  • Vehicle Unit #: ___________________

  • Year/Make: ___________________

  • VIN (Full 17 Digits): ______________________________________

  • License Plate: ___________________ State: _________

  • Odometer Reading: ___________________

  • Motor Carrier Name: ______________________________________

  • Carrier Address: ___________________________________________________________

SECTION 2: INSPECTION CHECKLIST

Mark each item: (S) Satisfactory | (R) Repair Required | (NA) Not Applicable

2.1 BRAKE SYSTEM (Standard: 49 CFR §393.40-55)

  • [ ] Service Brakes (Check for drum/rotor cracks, lining thickness)

  • [ ] Parking Brake System (Holds vehicle on grade)

  • [ ] Brake Hoses/Tubing (Check for bulges, leaks, or chafing)

  • [ ] Low Pressure Warning Device (Audible/Visual)

  • [ ] Tractor Protection Valve

  • [ ] Air Compressor (Build rate and governor cut-out)

  • [ ] ABS System (Warning lamp functional)

2.2 STEERING MECHANISM (Standard: 49 CFR §393.209)

  • [ ] Steering Wheel Free Play (Lash)

  • [ ] Steering Column/Universal Joints

  • [ ] Power Steering Pump & Fluid Levels

  • [ ] Tie Rods, Drag Links, and Pitman Arm

  • [ ] Steering Gear Box (Security and leaks)

2.3 SUSPENSION & FRAME (Standard: 49 CFR §393.201-207)

  • [ ] Leaf Springs/Air Bags (No cracks or leaks)

  • [ ] U-Bolts & Torque Arms (Secure/Not missing)

  • [ ] Frame Members (No cracks or sagging)

  • [ ] Adjustable Axle (Sliding subframe) locking pins

2.4 TIRES & WHEELS (Standard: 49 CFR §393.75 & §393.205)

  • [ ] Steer Tires (Min. 4/32″ tread, no regrooved tires)

  • [ ] Drive/Trailer Tires (Min. 2/32″ tread)

  • [ ] Wheel Rims (No cracks or elongated bolt holes)

  • [ ] Lug Nuts (Secure/None missing)

2.5 LIGHTING & ELECTRICAL (Standard: 49 CFR §393.11)

  • [ ] Headlamps (High/Low beam)

  • [ ] Turn Signals & Hazard Flashers

  • [ ] Tail, Stop, and Clearance Lamps

  • [ ] Reflectors and Retroreflective Sheeting (Conspicuity tape)

2.6 MISCELLANEOUS SAFETY

  • [ ] Exhaust System (No leaks beneath sleeper/cab)

  • [ ] Fuel System (Cap secure, no visible leaks)

  • [ ] Windshield Wipers/Washers (Functional/Blade condition)

  • [ ] Rear Impact Guard (Condition and placement)

  • [ ] Fifth Wheel/Coupling Devices (Jaw lock and security)

SECTION 3: REPAIR CERTIFICATION

If any item above was marked (R), this section must be completed before the vehicle returns to service.

  • Repair Date: ___________________

  • Work Order #: ___________________

  • Mechanic Name: ___________________

SECTION 4: INSPECTOR CERTIFICATION

I certify that this vehicle has been inspected in accordance with 49 CFR §396.17 and meets the minimum periodic inspection standards.

  • Inspector Name (Print): ______________________________________

  • Inspector Signature: ______________________________________

  • Qualification: [ ] Mechanic/Technician [ ] Registered Inspector

 

 

External References

Also read:  Compliance and Confidence: Mastering ELDs and Inspection Checklists

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