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Title 49 Part 396 Appx A

Inspection Standards

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Title 49 Part 396 Appx A

Inspection Standards

Vehicle Identification

1. Brake System

Brake Measurements (Stroke)

0% Defective (0/0)
RIGHT SIDE (CURB) Click to cycle defect status LEFT SIDE (DRIVER)

a. Service Brakes

  • (1) Absence of braking action on any axle required to have brakes upon application of the service brakes (such as missing brakes or brake shoe(s) failing to move upon application of a wedge, S-cam, cam, or disc brake). (1) Brakes not working on any required axle (missing parts or shoes don't move).
  • (2) Missing or broken mechanical components including: shoes, lining, pads, springs, anchor pins, spiders, cam rollers, push-rods, and air chamber mounting bolts. (2) Missing or broken parts (shoes, pads, springs, push-rods, bolts, etc.).
  • (3) Loose brake components including air chambers, spiders, and cam shaft support brackets. (3) Loose brake components (air chambers, brackets, etc.).
  • (4) Audible air leak at brake chamber (Example-ruptured diaphragm, loose chamber clamp, etc.). (4) Audible air leak at brake chamber.
  • (5) Readjustment limits. The maximum pushrod stroke must not be greater than the values given in the tables below and at § 393.47(e). Any brake stroke exceeding the readjustment limit will be rejected. Stroke must be measured with engine off and reservoir pressure of 80 to 90 psi with brakes fully applied. (5) Pushrod stroke exceeds adjustment limit (measure with engine off, 80-90 psi).
  • (6) Brake linings or pads. (a) Lining or pad is not firmly attached to the shoe; (b) Saturated with oil, grease, or brake fluid; or (c) Non-steering axles: Lining with a thickness less than 1/4 inch at the shoe center for air drum brakes, 1/16 inch or less at the shoe center for hydraulic and electric drum brakes, and less than 1/8 inch for air disc brakes. (d) Steering axles: Lining with a thickness less than 1/4 inch at the shoe center for drum brakes, less than 1/8 inch for air disc brakes and 1/16 inch or less for hydraulic disc and electric brakes. (6) Bad linings/pads: Loose, oil-soaked, or too thin (under 1/4" drum, 1/8" air disc).
  • (7) Missing brake on any axle required to have brakes. (7) Missing brake on a required axle.
  • (8) Mismatch across any power unit steering axle of: (a) Air chamber sizes. (b) Slack adjuster length. (8) Mismatched chamber size or slack adjuster length on steer axle.

b. Parking Brake System

  • No brakes on the vehicle or combination are applied upon actuation of the parking brake control, including driveline hand controlled parking brakes. Parking brake does not hold the vehicle.

c. Brake Drums or Rotors

  • (1) With any external crack or cracks that open upon brake application (do not confuse short hairline heat check cracks with flexural cracks). (1) Cracked drum or rotor (opens when brakes applied).
  • (2) Any portion of the drum or rotor missing or in danger of falling away. (2) Piece of drum/rotor missing or broken.

d. Brake Hose

  • (1) Hose with any damage extending through the outer reinforcement ply. (Rubber impregnated fabric cover is not a reinforcement ply). (Thermoplastic nylon may have braid reinforcement or color difference between cover and inner tube. Exposure of second color is cause for rejection. (1) Hose damaged: reinforcement ply exposed.
  • (2) Bulge or swelling when air pressure is applied. (2) Hose bulges or swells under pressure.
  • (3) Any audible leaks. (3) Audible leak.
  • (4) Two hoses improperly joined (such as a splice made by sliding the hose ends over a piece of tubing and clamping the hose to the tube). (4) Improper hose splice.
  • (5) Air hose cracked, broken or crimped. (5) Hose cracked, broken, or crimped.

e. Brake Tubing

  • (1) Any audible leak. (1) Audible leak.
  • (2) Tubing cracked, damaged by heat, broken or crimped. (2) Tubing cracked, heat damaged, broken, or crimped.

f-m. Other Systems

  • f. Low Pressure Warning Device: missing, inoperative, or does not operate at 55 psi and below, or 1/2 the governor cut-out pressure, whichever is less. f. Low Air Warning: Missing or doesn't work (must alert at 55 psi or below).
  • g. Tractor Protection Valve: Inoperable or missing tractor protection valve(s) on power unit. g. Tractor Protection Valve: Missing or broken.
  • h. Air Compressor: (1) Compressor drive belts in condition of impending or probable failure. (2) Loose compressor mounting bolts. (3) Cracked, broken or loose pulley. (4) Cracked or broken mounting brackets, braces or adapters. h. Air Compressor: Loose bolts, cracked pulley/brackets, or bad belt.
  • i. Electric Brakes: (1) Absence of braking action on any wheel required to have brakes. (2) Missing or inoperable breakaway braking device. i. Electric Brakes: Not working or missing breakaway device.
  • j. Hydraulic Brakes: (1) Master cylinder less than 1/4 full. (2) No pedal reserve with engine running except by pumping pedal. (3) Power assist unit fails to operate. (4) Seeping or swelling brake hose(s) under application of pressure. (5) Missing or inoperative check valve. (6) Has any visually observed leaking hydraulic fluid in the brake system. (7) Has hydraulic hose(s) abraded (chafed) through outer cover-to-fabric layer. (8) Fluid lines or connections leaking, restricted, crimped, cracked or broken. (9) Brake failure or low fluid warning light on and/or inoperative. j. Hydraulic Brakes: Leaks, pedal fades, power assist fail, or warning light on.
  • k. Vacuum Systems: Any vacuum system which: (1) Has insufficient vacuum reserve to permit one full brake application after engine is shut off. (2) Has vacuum hose(s) or line(s) restricted, abraded (chafed) through outer cover to cord ply, crimped, cracked, broken or has collapse of vacuum hose(s) when vacuum is applied. (3) Lacks an operative low-vacuum warning device as required. k. Vacuum System: Insufficient reserve, bad hoses, or no warning device.
  • l. Antilock Brake System: (1) Missing ABS malfunction indicator components (i.e., bulb, wiring, etc.). (2) ABS malfunction indicator that does not illuminate when power is first applied to the ABS controller (ECU) during initial power up. (3) ABS malfunction indicator that stays illuminated while power is continuously applied to the ABS controller (ECU). (4) ABS malfunction indicator lamp on a trailer or dolly does not cycle when electrical power is applied (a) only to the vehicle's constant ABS power circuit, or (b) only to the vehicle's stop lamp circuit. (5) With its brakes released and its ignition switch in the normal run position, power unit does not provide continuous electrical power to the ABS on any air-braked vehicle it is equipped to tow. (6) Other missing or inoperative ABS components. l. ABS: Warning light stays on, doesn't light up, or missing components.
  • m. Automatic Brake Adjusters: (1) Failure to maintain a brake within the brake stroke limit specified by the vehicle manufacturer. (2) Any automatic brake adjuster that has been replaced with a manual adjuster. (3) Damaged, loose, or missing components. (4) Any brake that is found to be out of adjustment on initial inspection must be evaluated to determine why the automatic brake adjuster is not functioning properly and the problem must be corrected in order for the vehicle to pass the inspection. m. Auto Slack Adjusters: Missing, damaged, or replaced with manual adjuster.

2. Coupling Devices

a. Fifth Wheels

  • (1) Mounting to frame. (a) Any fasteners missing or ineffective. (b) Any movement between mounting components. (c) Any mounting angle iron cracked or broken. (1) Mounting: Missing bolts, cracked mounts, or movement.
  • (2) Mounting plates and pivot brackets. (a) Any fasteners missing or ineffective. (b) Any welds or parent metal cracked. (c) More than 3/8 inch horizontal movement between pivot bracket pin and bracket. (d) Pivot bracket pin missing or not secured. (2) Pivot Brackets: Cracked welds/metal or worn pins (>3/8" play).
  • (3) Sliders. (a) Any latching fasteners missing or ineffective. (b) Any fore or aft stop missing or not securely attached. (c) Movement more than 3/8 inch between slider bracket and slider base. (d) Any slider component cracked in parent metal or weld. (3) Sliders: Bad latch, missing stops, cracked components, or excessive movement.
  • (4) Lower coupler. (a) Horizontal movement between the upper and lower fifth wheel halves exceeds 1/2 inch. (b) Operating handle not in closed or locked position. (c) Kingpin not properly engaged. (d) Separation between upper and lower coupler allowing light to show through from side to side. (e) Cracks in the fifth wheel plate. Exceptions: Cracks in fifth wheel approach ramps and casting shrinkage cracks in the ribs of the body of a cast fifth wheel. (f) Locking mechanism parts missing, broken, or deformed to the extent the kingpin is not securely held. (4) Lower Coupler: Handle not locked, jaws open, separation, or cracked plate.

b-f. Other Coupling

  • b. Pintle Hooks. (1) Mounting to frame. (a) Any missing or ineffective fasteners (a fastener is not considered missing if there is an empty hole in the device but no corresponding hole in the frame or vice versa). (b) Mounting surface cracks extending from point of attachment (e.g., cracks in the frame at mounting bolt holes). (c) Loose mounting. (d) Frame cross member providing pintle hook attachment cracked. (2) Integrity. (a) Cracks anywhere in pintle hook assembly. (b) Any welded repairs to the pintle hook. (c) Any part of the horn section reduced by more than 20%. (d) Latch insecure. b. Pintle Hook: Loose, cracked, worn (>20%), or bad latch.
  • c. Drawbar/Towbar Eye. (1) Mounting. (a) Any cracks in attachment welds. (b) Any missing or ineffective fasteners. (2) Integrity. (a) Any cracks. (b) Any part of the eye reduced by more than 20%. c. Drawbar Eye: Cracked or worn (>20%).
  • d. Drawbar/Towbar Tongue. (1) Slider (power or manual). (a) Ineffective latching mechanism (b) Missing or ineffective stop. (c) Movement of more than 1/4 inch between slider and housing. (d) Any leaking, air or hydraulic cylinders, hoses, or chambers (other than slight oil weeping normal with hydraulic seals). (2) Integrity. (a) Any cracks. (b) Movement of 1/4 inch between subframe and drawbar at point of attachment. d. Tongue: Slider movement >1/4", leaks, or cracks.
  • e. Safety Devices. (1) Safety devices missing. (2) Unattached or incapable of secure attachment. (3) Chains and hooks. (a) Worn to the extent of a measurable reduction in link cross section. (b) Improper repairs including welding, wire, small bolts, rope and tape. (4) Cable. (a) Kinked or broken cable strands. (b) Improper clamps or clamping. e. Safety Chains/Cables: Missing, unattached, worn, or improper repairs.
  • f. Saddle-Mounts. (1) Method of attachment. (a) Any missing or ineffective fasteners. (b) Loose mountings. (c) Any cracks or breaks in a stress or load bearing member. (d) Horizontal movement between upper and lower saddle-mount halves exceeds 1/4 inch. f. Saddle-Mounts: Loose, cracked, or worn parts.

3. Exhaust System

  • a. Any exhaust system determined to be leaking at a point forward of or directly below the driver/sleeper compartment. a. Leaks forward of or below driver/sleeper.
  • b. A bus exhaust system leaking or discharging to the atmosphere: (1) Gasoline powered—excess of 6 inches forward of the rearmost part of the bus. (2) Other than gasoline powered—in excess of 15 inches forward of the rearmost part of the bus. (3) Other than gasoline powered—forward of a door or window designed to be opened. (exception: Emergency exits). b. Bus exhaust discharge location incorrect.
  • c. No part of the exhaust system of any motor vehicle shall be so located as would be likely to result in burning, charring, or damaging the electrical wiring, the fuel supply, or any combustible part of the motor vehicle. c. Exhaust burning/damaging wiring or fuel lines.

4. Fuel System

  • a. A fuel system with a visable leak at any point. a. Visible fuel leak.
  • b. A fuel tank filler cap missing. b. Missing filler cap.
  • c. A fuel tank not securely attached to the motor vehicle by reason of loose, broken or missing mounting bolts or brackets (some fuel tanks use springs or rubber bushings to permit movement). c. Tank loose or missing bolts.

5. Lighting Devices

Regulation: All lighting devices and reflectors required by part 393 shall be operable. View § 393.11 Table 1

Head/Turn/Tail

  • Headlamps (High/Low)
  • Turn Signals (Front)
  • Turn Signals (Rear)
  • Tail/Stop Lamps

Markers & Reflectors

  • Side Markers (Front/Mid)
  • Side Markers (Rear)
  • Clearance/ID Lamps
  • Conspicuity (Top)
  • Conspicuity (Bottom)
  • License Plate/Backup

6. Safe Loading

  • a. Part(s) of vehicle or condition of loading such that the spare tire or any part of the load or dunnage can fall onto the roadway. a. Cargo/spare tire not secured (risk of falling).
  • b. Protection Against Shifting Cargo—Any vehicle without a front-end structure ("headache rack") or equivalent device as required. b. Missing or damaged front-end structure (headache rack).
  • c. Container securement devices on intermodal equipment—All devices used to secure an intermodal container to a chassis, including rails or support frames, tiedown bolsters, locking pins, clevises, clamps, and hooks that are cracked, broken, loose, or missing. c. Container securement: Broken/missing tiedowns, pins, or locks.

7. Steering Mechanism

a. Steering Wheel Free Play

On vehicles equipped with power steering the engine must be running.

Wheel DiameterManual LimitPower Limit
16"2"4 1/2"
18"2 1/4"4 3/4"
20"2 1/2"5 1/4"
22"2 3/4"5 3/4"

Record Measurements

b-j. Components

  • b. Steering Column. (1) Any absence or looseness of U-bolt(s) or positioning part(s). (2) Worn, faulty or obviously repair welded universal joint(s). (3) Steering wheel not properly secured. b. Column: Loose U-bolts, worn U-joint, or unsecured wheel.
  • c. Front Axle Beam and All Steering Components Other Than Steering Column. (1) Any crack(s). (2) Any obvious welded repair(s). c. Front Axle: Cracks or welded repairs.
  • d. Steering Gear Box. (1) Any mounting bolt(s) loose or missing. (2) Any crack(s) in gear box or mounting brackets. d. Gear Box: Loose bolts or cracked box/brackets.
  • e. Pitman Arm. Any looseness of the pitman arm on the steering gear output shaft. e. Pitman Arm: Loose on output shaft.
  • f. Power Steering. Auxiliary power assist cylinder loose. f. Power Steering: Loose cylinder.
  • g. Ball and Socket Joints. (1) Any movement under steering load of a stud nut. (2) Any motion, other than rotational, between any linkage member and its attachment point of more than 1/4 inch. g. Ball Joints: Movement under load.
  • h. Tie Rods and Drag Links. (1) Loose clamp(s) or clamp bolt(s) on tie rods or drag links. (2) Any looseness in any threaded joint. h. Tie Rods/Drag Links: Loose clamps or threads.
  • i. Nuts. Nut(s) loose or missing on tie rods, pitman arm, drag link, steering arm or tie rod arm. i. Nuts: Loose or missing.
  • j. Steering System. Any modification or other condition that interferes with free movement of any steering component. j. Modification interfering with free movement.

8. Suspension

  • a. Any U-bolt(s), spring hanger(s), or other axle positioning part(s) cracked, broken, loose or missing resulting in shifting of an axle from its normal position. (After a turn, lateral axle displacement is normal with some suspensions. Forward or rearward operation in a straight line will cause the axle to return to alignment). a. U-bolts/Spring Hangers: Cracked, broken, loose, or shifting axle.
  • b. Spring Assembly. (1) Any leaves in a leaf spring assembly broken or missing. (2) Any broken main leaf in a leaf spring assembly. (Includes assembly with broken main leaf). (3) Coil spring broken. (4) Rubber spring missing. (5) One or more leaves displaced in a manner that could result in contact with a tire, rim, brake drum or frame. (6) Broken torsion bar spring in a torsion bar suspension. (7) Deflated air suspension, i.e., system failure, leak, etc. b. Springs: Broken/missing leaves, coil springs, or torsion bars. Deflated air bag.
  • c. Torque, Radius or Tracking Components. Any part of a torque, radius or tracking component assembly or any part used for attaching the same to the vehicle frame or axle that is cracked, loose, broken or missing. (Does not apply to loose bushings in torque or track rods.) c. Torque/Radius Rods: Cracked, loose, or missing parts.

9. Frame

  • a. Frame Members. (1) Any cracked, broken, loose, or sagging frame member. (2) Any loose or missing fasteners including fasteners attaching functional component such as engine, transmission, steering gear, suspension, body parts, and fifth wheel. a. Frame Members: Cracked, broken, sagging, or loose fasteners.
  • b. Tire and Wheel Clearance. Any condition, including loading, that causes the body or frame to be in contact with a tire or any part of the wheel assemblies. b. Tire Clearance: Tire rubbing against frame/body.
  • c. (1) Adjustable Axle Assemblies (Sliding Subframes). Adjustable axle assembly with locking pins missing or not engaged. c. Sliding Subframe: Locking pins missing or not engaged.

10. Tires

Tire Pressure Matrix

RIGHT SIDE (CURB) Left=Front, Right=Rear LEFT SIDE (DRIVER)

a. Any tire on any steering axle of a power unit.

  • (1) With less than 4/32 inch tread when measured at any point on a major tread groove. (1) Tread depth less than 4/32 inch.
  • (2) Has body ply or belt material exposed through the tread or sidewall. (2) Belt material exposed.
  • (3) Has any tread or sidewall separation. (3) Tread or sidewall separation.
  • (4) Has a cut where the ply or belt material is exposed. (4) Cut exposing ply/belt.
  • (5) Labeled “Not for Highway Use” or displaying other marking which would exclude use on steering axle. (5) Marked 'Not for Highway Use'.
  • (6) A tube-type radial tire without radial tube stem markings. (6) Radial tire missing tube stem markings.
  • (7) Mixing bias and radial tires on the same axle. (7) Mixed bias and radial tires.
  • (8) Tire flap protrudes through valve slot in rim and touches stem. (8) Tube flap touching stem.
  • (9) Regrooved tire except motor vehicles used solely in urban or suburban service (see exception in § 393.75(e). (9) Regrooved tire (unless allowed).
  • (10) Boot, blowout patch or other ply repair. (10) Boot or blowout patch.
  • (11) Weight carried exceeds tire load limit. (11) Overweight (exceeds load limit).
  • (12) Tire is flat or has noticeable (e.g., can be heard or felt) leak. (12) Flat or audible leak.
  • (13) Any bus equipped with recapped or retreaded tire(s). (13) Retread on bus steer axle.
  • (14) So mounted or inflated that it comes in contact with any part of the vehicle. (14) Tire touching vehicle.

b. All tires other than those found on the steering axle of a power unit:

  • (1) Weight carried exceeds tire load limit. (1) Overweight (exceeds load limit).
  • (2) Tire is flat or has noticeable (e.g., can be heard or felt) leak. (2) Flat or audible leak.
  • (3) Has body ply or belt material exposed through the tread or sidewall. (3) Belt material exposed.
  • (4) Has any tread or sidewall separation. (4) Tread or sidewall separation.
  • (5) Has a cut where ply or belt material is exposed. (5) Cut exposing ply/belt.
  • (6) So mounted or inflated that it comes in contact with any part of the vehicle. (This includes a tire that contacts its mate.) (6) Tire touching vehicle or mate.
  • (7) Is marked “Not for highway use” or otherwise marked and having like meaning. (7) Marked 'Not for Highway Use'.
  • (8) With less than 2/32 inch tread when measured at any point on a major tread groove. (8) Tread depth less than 2/32 inch.
  • c. Installation of speed-restricted tires unless specifically designated by motor carrier. c. Speed-restricted tire violation.

11. Wheels & Rims

  • a. Lock or Side Ring. Bent, broken, cracked, improperly seated, sprung or mismatched ring(s). a. Lock/Side Ring: Bent, broken, or mismatched.
  • b. Wheels and rims. Cracked or broken or has elongated bolt holes. b. Wheels/Rims: Cracked, broken, or elongated holes.
  • c. Fasteners (both spoke and disc wheels). Any loose, missing, broken, cracked, stripped or otherwise ineffective fasteners. c. Fasteners: Loose, missing, broken, cracked, stripped.
  • d. Welds. (1) Any cracks in welds attaching disc wheel disc to rim. (2) Any crack in welds attaching tubeless demountable rim to adapter. (3) Any welded repair on aluminum wheel(s) on a steering axle. (4) Any welded repair other than disc to rim attachment on steel disc wheel(s) mounted on the steering axle. d. Welds: Cracks in welds or unauthorized repairs.

12. Windshield Glazing

  • (Not including a 2 inch border at the top, a 1 inch border at each side and the area below the topmost portion of the steering wheel.) Any crack, discoloration or vision reducing matter except: (1) coloring or tinting applied at time of manufacture; (2) any crack not over 1/4 inch wide, if not intersected by any other crack; (3) any damaged area not more than 3/4 inch in diameter, if not closer than 3 inches to any other such damaged area; (4) labels, stickers, decalcomania, etc. (see § 393.60 for exceptions). Crack or damage obstructing view (in wiper sweep area).

13. Windshield Wipers

  • Any power unit that has an inoperative wiper, or missing or damaged parts that render it ineffective. Wiper inoperative, missing, or damaged.

14. Motorcoach Seats

  • a. Any passenger seat that is not securely fastened to the vehicle structure. a. Seat not securely fastened.

15. Rear Impact Guard

  • a. Trailers and semitrailers with a GVWR of 4,536 kg (10,001 lbs.) or more, manufactured on or after January 26, 1998. (1) Missing guard. (2) Guard is not securely attached to trailer. (3) Guard does not extend to within 100 mm (4 inches) of each side. (4) Guard is more than 560 mm (22 inches) above the ground. (5) Guard is more than 305 mm (12 inches) forward of rear. (6) Guard height < 100 mm (4 inches). a. Guard missing or not securely attached.
  • b. Commercial motor vehicles manufactured after December 31, 1952 (except trailers above). (1) Missing guard. (2) Guard is not securely attached. (3) Guard > 762 mm (30 inches) above ground. (4) Guard does not extend to within 457 mm (18 inches) of each side. (5) Guard > 610 mm (24 inches) forward of rear. b. Guard dimensions incorrect (height/width/position).

16. Additional Safety Requirements

Regulations found in 49 CFR Part 393 (Parts and Accessories Necessary for Safe Operation).

Defrost, Horn, & Seatbelts (Subpart G)

  • § 393.79 Defrosting/Defogging: Windshield defrosting and defogging systems must be operative. Defroster/Defogger not working.
  • § 393.81 Horn: Every bus, truck, and truck-tractor must be equipped with a horn and means of actuating it. Horn inoperative.
  • § 393.93 Seatbelts: Seats, seat belt assemblies, and seat belt assembly anchorages must be installed and operative. Seatbelt missing, frayed, or latch broken.

Emergency Equipment (§ 393.95)

  • § 393.95(a) Fire Extinguishers: Must be securely mounted, gauge in green (if applicable), and proper rating. Fire extinguisher missing, discharged, or not secured.
  • § 393.95(c) Spare Fuses: Required for any power unit that uses fuses for required parts/accessories; requires at least one spare of each type/size. Spare fuses missing (if applicable).
  • § 393.95(f) Triangles: Specifies the requirement for three bidirectional emergency reflective triangles, or alternatives like fusees/liquid-burning flares. 3 Reflective Triangles missing or damaged.

Trailer Inspection

Refer to the specific sections above for regulatory text. This list aggregates trailer-specific components found in Appendix A.

  • Frame/Body: Rails cracked or holes in floor.
  • Landing Gear: Pads missing or handle broken.
  • Doors/Ties: Hinges broken or latches insecure.
  • Conspicuity: Tape missing or damaged.
  • Air Lines: Dragging, leaking, or chafed.
  • Lights: All trailer lights must work.

Generated for Title 49 Part 396 Appendix A Compliance.