Safety Truck Inspections 2025: How to Stay Compliant and Avoid Fines?

Alright, let’s keep it real - being a trucker isn’t just about driving. It’s about mastering the rules, meeting deadlines, and maintaining your rig. 

But here’s the thing: 2025 is shaping up to be a big year for inspections and truck safety checks. Imagine cruising down the highway when you spot those flashing blue lights behind you. The result of your inspection will be determined by your preparedness.

The good news? You don’t have to stress. Whether it’s the annual DOT Blitz Week, the CVSA Roadcheck, or random roadside inspections, we’ll walk you through everything you need to know to stay compliant, avoid costly fines, and keep your wheels rolling. Let’s dive into the list of safety truck inspections for 2025.

1. 90-Day Truck Inspection

While the federal government doesn’t mandate 90-day inspections, many carriers require them as part of their internal safety programs. These periodic checks help catch minor issues before they escalate into major problems. Think of it as a preventive maintenance strategy that keeps your truck running smoothly and avoids costly breakdowns or violations during roadside checks.

For example, a small issue like a worn brake pad might seem insignificant, but if left unchecked, it could lead to an accident. Studies show that fleets conducting regular 90-day inspections experience 30% fewer breakdowns and save thousands in repair costs annually. 

One fleet manager in Ohio reported a 25% drop in CSA scores after implementing a strict 90-day inspection schedule, which not only improved safety but also reduced penalties and downtime.

What Are the Main Requirements?

Only certified mechanics or authorized facilities can perform a 90-day inspection. To find one near you, search for 90-day BIT inspection near me or consult your carrier’s approved list. Once the inspection is complete, the mechanic will provide a detailed report outlining findings, repairs made, and recommendations for future maintenance. Keep this report in your cab - it’s proof of your commitment to safety and can be a lifesaver during audits or roadside checks.

During a 90-day inspection, inspectors will thoroughly examine your vehicle to ensure it meets all safety standards. They will check various components and systems, such as:

- Brakes
Inspectors will check air lines for leaks, cracks, or corrosion, as even a small issue can compromise braking performance. They measure the thickness of brake pads and drums, ensuring there’s no uneven wear that could reduce stopping power and increase accident risks. Proper adjustment is also critical. Misaligned brakes can cause uneven tire wear and decreased vehicle stability.

- Tires
Inspectors use tread depth gauges to confirm that tires meet the minimum requirement of 2/32 inches, with steer tires needing at least 4/32 inches of tread. They also examine the condition of the tires, checking for any cuts, bulges, or exposed cords, which could lead to an out-of-service order if found. Proper inflation is another key focus, as underinflated or overinflated tires are a common violation. Drivers should use a reliable tire gauge to check pressure weekly.

- Lights
All bulbs must be functional, and inspectors often use flashlights to identify burned-out bulbs during checks. Lenses must be clean and free of cracks, as dirty or cracked lenses reduce visibility and may result in citations. Tail and brake lights are inspected to ensure they’re visible from 500 feet. Regularly testing lights and carrying spare bulbs in the cab is a smart way to stay compliant.

- Cargo Securement
Chains and straps are inspected for rust, fraying, or stretching, as weak securement devices can lead to shifting loads or falling cargo. Tarps are also checked for tears or missing grommets, which can compromise the integrity of the load. Properly securing cargo using diagrams and inspecting equipment before every trip can prevent violations.

In addition to exterior checks, the 90-day inspection includes a thorough evaluation of the truck’s interior. This ensures that all critical components, both inside and outside the vehicle, are assessed for safety and compliance. To give you a better understanding of what this process entails, check out the video below. 

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Drivers who skip 90-day inspections often face unexpected breakdowns, costly repairs, and even out-of-service orders during random checks. For instance, a driver in California was pulled over during a routine inspection and found to have multiple brake violations. The resulting downtime cost him nearly $10,000 in lost wages and repairs. On the flip side, drivers who stay proactive by addressing minor issues early avoid these headaches entirely.

To ensure you’re ready, track your 90-day inspections using a logbook or digital app. Also, inspect your truck regularly yourself: measure tread depth, test lights, and check tire pressure weekly. If you notice any issues, address them immediately. A little extra effort now can save you from major headaches later.

2. CVSA Roadcheck 2025

The CVSA Roadcheck (May 13–15) is a high-visibility, high-volume commercial motor vehicle inspection and regulatory compliance enforcement initiative that takes place over three days in Canada, Mexico, and the United States. This year's focus areas are tires and false records of duty status (RODS).  Let’s break down what you need to know to prepare effectively.

During CVSA Roadcheck, inspectors will meticulously evaluate tires for any issues that could compromise safety. Here’s what they’ll be checking for:

- Air Leaks. Listen for any hissing sounds that tell you air is escaping.

- Bulges and Separations. Look closely at the sidewall for any bulges or spots where the tread or sidewall is coming apart.

- Cuts and Exposed Casing. Keep an eye out for cuts or places where the belt material or casing ply is showing through the tread or sidewall.

- Flat Tires. Obviously, check if any tires are flat.

- Foreign Objects. Look for anything stuck between dual tires.

- Improper Repairs. See if there are any signs of shoddy repairs, like rubber plugs in the sidewall.

-  Low Tread Depth. Make sure there's enough tread left on the tires.

In addition to tire inspections, the FMCSA has strict rules about how long commercial truck drivers can be on the road. These hours-of-service regulations are designed to prevent driver fatigue and ensure safety for everyone on the road. During CVSA Roadcheck, inspectors will closely review drivers’ records of duty status (RODS) to catch those who fail to comply. 

Inspectors are on the lookout for violations like messing with electronic logging devices. This includes things like driving without logging in, disconnecting the device, or making shady edits to your logs. They're also keeping an eye out for drivers who try to pull a fast one by falsely claiming to have a co-driver, improper use of the personal conveyance rule, or applying exemptions for bad driving conditions. And they're not going to let you slide if you claim to be off-duty while still doing work-related stuff.

3. DOT Blitz Week 2025

DOT Blitz Week (June 13–15) is an annual, high-intensity enforcement initiative conducted by the Department of Transportation (DOT) and the Commercial Vehicle Safety Alliance (CVSA). It is one of the most significant safety crackdowns in the trucking industry, designed to ensure compliance with federal safety regulations. During this event, law enforcement agencies across North America conduct heightened roadside inspections on commercial vehicles and drivers to identify violations and promote safer roadways.

Unlike routine inspections, this event involves widespread enforcement efforts, making it a pivotal moment for the industry. The goal is not only to catch violations but also to reinforce the importance of proactive maintenance and adherence to regulations throughout the year.

Failing an inspection during DOT Blitz Week can result in severe consequences, including out-of-service orders, fines, and damage to a carrier’s Compliance, Safety, Accountability (CSA) score. This makes it a critical event for drivers and fleet operators to approach with diligence and attention to detail. By understanding the emphasis areas and ensuring compliance, participants can avoid penalties and contribute to a safer transportation environment.

In 2024, 1 in 5 trucks failed Blitz Week inspections. Avoid being that statistic by understanding the focus areas and preparing thoroughly. Here’s what you need to focus on:

- Truck Inspection
The truck inspection during DOT Blitz Week includes all the same requirements as the 90-Day Truck Inspection, ensuring your vehicle is roadworthy and compliant.

- Driver Documentation
Driver documentation is another critical focus area during inspections. A valid and up-to-date CDL is mandatory, as expired licenses result in automatic out-of-service orders. Medical cards must also be current and easily accessible, as missing or expired cards are a frequent issue during inspections. For driver documentation, keep your CDL, medical card, and ELD logs in a folder in your cab. Update your ELD logs in real time to avoid discrepancies.

 A veteran inspector in Florida shared: “Drivers who have their papers ready before I even ask make a great impression. It shows they’re organized and professional.”

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4. Annual Inspection Deadline

The DOT annual inspection (starting on December 31, 2025) is a federally mandated evaluation required for all commercial vehicles. It ensures that your truck meets minimum safety standards and remains roadworthy throughout the year. Miss it, and you’re grounded. Pass it, and you get a DOT inspection sticker.

During the annual inspection, certified mechanics evaluate every aspect of your vehicle. In addition to the standard requirements covered in other inspections (such as brakes, tires, lights, and cargo securement), the following areas are also thoroughly assessed:‍

- Exhaust System. The exhaust system is inspected for leaks, rust, or damage. A malfunctioning exhaust system can lead to hazardous fumes entering the cab or reduced engine performance.‍

- Coupling Devices. Coupling devices (e.g., fifth wheels, kingpins, and trailer connections) are checked for proper alignment, lubrication, and security. Faulty coupling devices can lead to trailer separation, posing a severe safety risk.‍

- Steering and Suspension. The steering system is evaluated for excessive play or damage, as loose steering components can compromise vehicle control. The suspension system is inspected for wear, damage, or misalignment, as a faulty suspension affects ride quality, vehicle stability, and overall safety.‍

- Windshield. The windshield must be free of cracks, chips, or obstructions that impair visibility. Damaged windshields can result in citations and must be repaired or replaced before the inspection.

- Safe Loading. Cargo securement is evaluated to ensure loads are properly balanced and secured. Inspectors check chains, straps, and tarps for rust, fraying, or stretching. Weak securement devices can lead to shifting loads or falling cargo, endangering everyone on the road.‍

- Safety Equipment. Inspectors verify that the required safety equipment is present and functional. The fire extinguisher must be fully charged and accessible, while reflective triangles must be carried (at least three) and kept in good condition. Spare fuses are also required to address electrical issues, and additional safety equipment, such as emergency lighting or warning devices, may be inspected depending on the vehicle type.

Failing to complete your annual inspection by December 31, 2025, can result in hefty fines, downtime, and even suspension of your operating authority. 

To ensure you’re ready, schedule your inspection by December 1 to avoid last-minute chaos. Conduct a pre-inspection yourself to identify potential issues. Address repairs immediately. A clean, well-maintained vehicle makes a great first impression on inspectors.

5. Random Roadside Inspections: Year-Round

Random roadside inspections can happen anytime, anywhere. Unlike scheduled events like DOT Blitz Week or CVSA Roadcheck, these inspections are completely unpredictable. Inspectors might pull you over for a Level 1 inspection or a Level 3 inspection (driver-only).

In 2024, 20% of all out-of-service orders occurred during random roadside checks. These inspections are a key tool for enforcing safety standards and ensuring compliance across the industry.

For example, a driver in Nevada was pulled over during a random inspection and found to have improperly secured cargo. The load shifted during transit, causing significant damage to the trailer. Had the driver been prepared, this costly incident could have been avoided.

Remember, preparation is your greatest ally. By performing regular pre-trip inspections, maintaining organized documentation, and proactively addressing issues before they escalate into problems, one will ensure successful inspections, enhance operational efficiency, minimize downtime, and establish a reputation as a dependable driver or fleet operator.

Are you ready for the unexpected? Take a moment to review your documentation and inspect your truck. Small actions that can save you from big headaches later.

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