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Cargo Van 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
Good news — most DOT inspection rules don't apply to you.
Cargo vans under 10,001 lbs GVWR are generally exempt from federal DOT inspections, annual vehicle inspections, ELD requirements, and medical card requirements. You still need a valid driver's license and should maintain your vehicle for safety.
Document Checklist
Medical card, annual inspection, ELD logs, IFTA decal, and IRP cab card are NOT required for vehicles under 10,001 lbs GVWR.
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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 |
|---|---|---|---|
| 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. |
| Windshield / wipers | Low | Sometimes | Replace cracked windshield (cracks in driver's field of vision = OOS). Check wiper blades monthly. |
OOS = Out of Service — the inspector can park your truck until the issue is fixed. You cannot drive until repairs are made.
Showing general vehicle safety items only. Full DOT-specific violations apply to vehicles over 10,001 lbs.
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.
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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.
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