Guides
Box Truck DOT Inspection Checklist
Know exactly what DOT inspectors check for your vehicle type. Cargo van drivers: you may be exempt from most inspections. Box truck operators: here's your complete prep checklist.
Equipment Type
Full DOT inspection scope applies to your vehicle.
Box trucks are subject to all DOT inspections. Medical card required. Annual vehicle inspection required. No CDL required (under 26K lbs). ELD required unless you qualify for short-haul exemption (150 air-mile radius, return within 14 hours) or 8-in-30 day paper log rule.
Document Checklist
Progress is saved on this device.
Pre-Trip Inspection Routine
- 1
Approach
Walk toward the vehicle. Check for leaks under the vehicle (oil, coolant, fuel). Note overall condition.
- 2
Engine Compartment
Check fluid levels (oil, coolant, power steering, washer). Inspect belts and hoses for wear or cracks.
- 3
Front of Vehicle
Headlights (high and low beam), turn signals, windshield condition, wiper blades, license plate and light.
- 4
Driver Side
Mirror condition and adjustment, door operation, fuel tank (cap secure, no leaks), tires (tread depth, inflation, lug nuts, sidewall condition).
- 5
Rear of Vehicle
Taillights, brake lights, turn signals, reflectors, reflective tape, cargo door operation, load securement.
- 6
Passenger Side
Mirror condition, tires, exhaust system (no leaks, properly mounted).
- 7
Cab Interior
All gauges operational, steering wheel play (no more than 2" free play), horn, seatbelt, emergency equipment (fire extinguisher, reflective triangles).
Common Violations & Fix-It Guide
| Violation | Severity | OOS? | How to Prevent |
|---|---|---|---|
| Brake adjustment / components | High | Yes | Pre-trip: check brake stroke, listen for air leaks. Adjustment out of spec is the #1 OOS violation. |
| Tire tread depth / condition | High | Yes | Minimum 4/32" on steer tires, 2/32" on drive tires. Check sidewalls for cuts, bulges, exposed cord. |
| Lighting / reflectors | High | Sometimes | 28% of all roadside violations (CVSA 2024). Walk-around check: all headlights, taillights, turn signals, brake lights, marker lights, reflectors. Replace burned bulbs immediately. |
| Hours of Service violation | Medium | Yes | Keep ELD logs current. Don't drive past the 11-hour driving limit or 14-hour on-duty window. |
| Expired medical card | Medium | Yes | Set a calendar reminder 60 days before expiration. Renewal takes 1–2 weeks. |
| No annual vehicle inspection | Medium | Yes | Schedule annually. Keep the inspection report in the vehicle at all times. |
| Windshield / wipers | Low | Sometimes | Replace cracked windshield (cracks in driver's field of vision = OOS). Check wiper blades monthly. |
| Leaking fluids | Medium | Sometimes | Check under vehicle before departure. Oil, coolant, or fuel leaks can result in OOS. |
OOS = Out of Service — the inspector can park your truck until the issue is fixed. You cannot drive until repairs are made.
The most thorough inspection. Inspector checks driver credentials AND performs a complete vehicle mechanical exam (including crawling under the vehicle).
What's checked
- Driver's license and endorsements
- Medical card (DOT Medical Examiner's Certificate)
- Hours of Service logs (ELD or paper)
- Vehicle registration and insurance
- Brake system (adjustment, components, air leaks)
- Steering and suspension
- Frame and body
- Tires and wheels (tread depth, inflation, lug nuts)
- Exhaust system
- Lighting and reflectors
- Coupling devices (if tractor-trailer)
- Fuel system
- Windshield and wipers
Frequency: Level I + Level II account for 90%+ of all inspections combined. Level I is the most thorough — takes 30–60 minutes.
Driver credentials check plus exterior vehicle walk-around. Inspector does NOT crawl under the vehicle.
What's checked
- Everything in driver credential check (license, medical card, HOS)
- Exterior walk-around: tires, lights, leaks, body damage, load securement
- No under-vehicle inspection
Frequency: Most common single inspection type. Takes 15–30 minutes.
Driver credentials only. No vehicle inspection.
What's checked
- License class and endorsements
- Medical card validity
- HOS compliance (ELD or paper logs)
- Drug and alcohol testing (if selected for random)
- Seatbelt use
Frequency: Less common than Level I/II. Quick — 10–15 minutes.
One-time examination of a specific item (e.g., a recall check or specific safety concern).
Frequency: Rare. Usually targeted.
Vehicle mechanical inspection without the driver present (e.g., parked truck at a facility).
Frequency: Rare.
Enhanced inspection for vehicles carrying hazardous materials. Includes radiological checks for certain materials.
Frequency: Only for hazmat carriers. Not applicable to most expedited carriers.
Download
DOT Inspection Prep by Equipment
Select your equipment type to see a tailored checklist with only the requirements that apply to your vehicle class.
Mostly Exempt
Under 10,001 lbs GVWR — exempt from most federal DOT requirements.
Partial Compliance
10,001–26,000 lbs GVWR — subject to DOT inspections but exempt from CDL, IFTA, and IRP.
Full Compliance
Full DOT scope applies. Box trucks avoid CDL; semis require everything.
These tools are provided for informational purposes and should not be treated as legal, tax, or financial advice.