Top Reasons Trucks Fail DOT Inspections—and How to Avoid Them

At Peach State Trucks, we know that maintaining your fleet’s reliability and roadworthiness isn’t just about uptime—it’s about compliance, safety, and reputation. DOT inspections are no joke: failures can halt operations, rack up fines, damage your CSA score, and even result in out-of-service orders.

Here’s a deep dive into the most frequent inspection failures—and how consistent maintenance and proactivity can keep your fleet rolling smoothly.

What happens:

Inspections often uncover worn brake pads, air-brake leaks, damaged hoses, or misadjusted systems. These are among the top reasons vehicles receive out-of-service orders.

How to avoid it:

• Schedule routine checks of pads, drums, and chambers.
• Perform air-leak tests, especially after long hauls.
• Adjust brakes per manufacturer specs.
• Address every brake warning light and audit all brake-related DVIR entries.

What inspectors see:

Issues include underinflation, tread worn below DOT standards, sidewall damage, and loose or missing fasteners.

Preventive steps:

• Daily inflation checks and tread-depth measurements.
• Rotate and align tires at proper intervals.
• Inspect rims for cracks, impact damage, and secure mounting.

Typical failures:

Non-functioning headlights, clearance lights, turn signals, marker lights, wiring corrosion, or ground-faulting are common inspection failures.

Your fix-it plan:

• Confirm all lights and reflector assemblies are operational and visible.
• Replace bulbs proactively.
• Keep wiring tidy, connectors tight, and grounds corrosion-free.

Frequent paperwork failures:

Missing or expired CDLs, medical certificates, inspection reports, log violations, incomplete DVIRs, or false logs are instant violations.

Compliance checklist:

• Drivers must carry valid, current licensing and medical cards.
• Maintain daily pre  and post trip DVIRs and retain them as per 49 CFR 396.11
• Use ELDs to reliably capture Hours-of-Service and prevent log omissions and falsifications .
• Conduct periodic audits to catch missing or incomplete documentation.

What inspectors look for:

Improperly secured cargo elements and over  or under gross weight infractions can lead to out-of-service directives.

Best practices:

• Train drivers on FMCSA’s cargo securement standards.
• Check straps, chains, tie-down points, and integrity before departure.
• Weigh trucks regularly to ensure compliance with the Federal Bridge Formula and state limits.

Typical failures:

Leaky fuel or DEF lines, exhaust leaks, and failed emissions are common DOT defects.

Inspection readiness:

• Include fuel and exhaust systems in your daily visual checks.
• Listen for unusual sounds or exhaust odors.
• Replace worn hoses and fasteners—and never run a rig with a known leak.

According to FMCSA guidance, the most common violations are preventable through disciplined pre trip routines, proactive upkeep, and thorough documentation . Here’s your action plan:

Daily Walk Arounds

• Confirm brakes, tires, lights, and cargo securement.
• Fill out precise DVIRs—include every defect.
• Ensure drivers leave the yard with safe, compliant rigs.

Routine Fleet Checks

• Schedule inspections by certified mechanics.
• Log all corrective actions and verify repairs before redeployment.

Driver Training & Records Management

• Ensure CDL and medical cards are valid—track renewals.
• Use ELDs to eliminate log errors.
• Audit driver logs and DVIRs regularly for completeness.

Review CSA/FMCSA Reports

• Monitor your carrier Safety Measurement System scores.
• Follow up immediately on any warnings or out-of-service orders.

• Avoid unplanned downtime: Clean inspections keep your fleet on the road and on schedule.
• Cut fines & repair costs: Typos, documentation gaps, and minor defects can grow into costly penalties.
• Maintain strong CSA scores: A solid safety rating supports better business, safer insurance rates, and customer trust.

DOT inspectors aren’t out to catch you—they’re focused on keeping highways safe. By adopting daily inspections, maintaining diligent maintenance schedules, and reinforcing driver training, you’re not just passing inspections—you’re building reputation, reliability, and roadworthy pride.

Have questions or need to schedule service? Use the service form at the bottom of this page to get in touch with our team, or submit a contact form for general inquiries here.