If you’re a truck owner or operator, it’s common knowledge that DOT inspections are required. However, a large number of fleets often find out about them the hard way, when a defective equipment inspection results in penalties, delays, or even being taken out of service. A failed DOT inspection, regardless of the size of your operation, will have a big impact on your finances.
Thankfully, there’s also good news. You can usually avoid most failures. If you get ready well and keep a disciplined driving style, you won’t have to stress out every time you see the lights in front of you. This blog explains why fleets don’t pass DOT inspections and explains what you can do to maintain road readiness.
1. Brakes: The #1 Problem Year After Year
No surprise here, brake issues top the list almost every year during roadside DOT inspections. Worn-out pads, air leaks, or out-of-adjustment brakes will get you dinged fast. Inspectors know a brake issue isn’t just a mechanical problem it’s a safety risk.
How to fix it:
Make brake checks a non-negotiable part of your pre-trip and PM schedule.
Teach drivers to recognize air pressure loss and unusual sounds.
Don’t wait until you hear grinding to replace components.
If your shop is missing these issues during routine maintenance, it might be time to review its inspection checklist or switch to a shop that understands how important brakes really are.
2. Lights and Reflectors: Small Fixes, Big Penalties
It sounds basic, but you’d be shocked how many trucks fail inspections for things like broken tail lights, missing reflectors, or non-functioning turn signals. These are usually easy to fix but just as easy to overlook.
How to fix it:
Make walkarounds part of every pre-trip and post-trip.
Keep a stash of spare bulbs and fuses in every truck.
Make sure every driver knows how to replace a light if needed.
These are fast wins. Don’t let a $2 light bulb knock your truck out of service.
3. Tires: More Than Just Tread
Tire damage, uneven wearing, and air pressure too low can result in your vehicle failing the test. Inspectors will carefully look for cords that are showing, any big swelling, and low air pressure. The look of your tires isn’t as important as how they operate.
How to fix it:
Use a tread depth gauge regularly, not just a visual check.
Monitor inflation with digital pressure gauges.
Address alignment issues that cause uneven wear before they eat up your tires.
Your tires aren’t just expensive, they’re also your first line of defense in an emergency. Treat them like it.
4. Load Securement: Easy to Miss, Costly to Fail
If you’re hauling flatbed loads, this is especially critical. But even dry vans can get hit if cargo isn’t properly secured. Shifting loads not only damage freight, they’re dangerous to everyone on the road.
How to fix it:
Train your drivers on FMCSA load securement rules.
Use the right tie-downs, straps, and bars; don’t “make do” with what’s lying around.
Have your techs inspect securement equipment regularly during PMs.
Load securement failures can get you an immediate out-of-service violation, and that’s the kind of downtime nobody can afford.
5. Driver Credentials and Logs: Tech Can Help If You Use It Right
Even if your truck passes inspection, your driver can still fail it. Missing medical cards, expired CDLs, or incomplete electronic logs can bring your score down fast.
How to fix it:
Set up reminders for expiring licenses, med cards, and training updates.
Make sure ELDs are fully functional and that your drivers know how to use them.
Double-check that logs are up to date and match the current trip.
DOT officers will ask questions. Make sure your drivers are trained and confident with their answers.
6. Steering and Suspension Issues
Sloppy steering or worn suspension components may not always be obvious to a driver but can spell disaster during a detailed inspection. Inspectors check for excessive play, worn kingpins, and leaking shocks.
How to fix it:
Include steering and suspension in every preventive maintenance inspection.
Address complaints about vehicle handling right away.
Don’t assume it’s “just an alignment” until someone gets under the truck.
If it affects handling, it affects safety, and inspectors know that.
7. Fluid Leaks and Engine Problems
Oil leaks, coolant drips, or fuel seepage can lead to environmental citations and mechanical red flags. They’re also a signal that your equipment isn’t being properly maintained.
How to fix it:
Have your techs check for leaks during every PM.
Clean your engine bay; it’s easier to spot fresh leaks on a clean surface.
Don’t ignore puddles where your trucks park.
Leaks are often a sign of bigger problems coming. Fix the small stuff now to avoid major downtime later.
Why These Issues Keep Happening
Let’s be real: most fleets don’t fail inspections because they don’t care. They fail because:
They’re short-staffed or stretched thin.
PM schedules are inconsistent or reactive.
Drivers aren’t trained to spot problems or feel pressured to run “as-is.”
The shop isn’t catching what matters most.
If this sounds familiar, it’s time to tighten up the process.
How to Turn It Around Fast
You don’t need to overhaul your whole operation overnight. But a few focused moves can make a big difference.
Work With a Shop That Knows DOT Rules
Partnering with a repair shop that understands what inspectors look for is a game-changer. If your provider doesn’t build DOT inspections into their regular PMs, find one that does.
Build a Pre-Trip and PM Culture
Train your drivers to treat pre-trips seriously, not just check-the-box exercises. Then back it up with solid PM scheduling and clear communication with your shop.
Use Tech That Works (and That You’ll Actually Use)
Even basic mobile apps can help drivers log pre-trips, flag issues, and stay compliant. You don’t need a massive system, just something simple that keeps everyone on the same page.
Make Accountability a Team Thing
DOT compliance isn’t just a driver issue or a shop issue, it’s a whole-fleet issue. Set clear expectations for everyone, from dispatch to maintenance, and create a loop that catches problems before they roll out the gate.
The Real Cost of Failing DOT Inspections
Every failed inspection carries a price:
Fines and penalties
Out-of-service orders
CSA score damage
Lost freight opportunities
Unhappy customers
And let’s not forget what it does to driver morale. Getting pulled over and slapped with a violation doesn’t exactly make a driver’s day.
But the flip side is true too passing DOT inspections consistently builds your reputation, improves your safety scores, and gives you a leg up when negotiating freight.
Final Thoughts: Stay Ready, Stay Rolling
DOT inspections aren’t going anywhere. But failed inspections don’t have to be part of your story. Most of what knocks trucks out of service can be caught with better habits, sharper training, and smarter partnerships.
The right DOT inspections partner will do more than just check boxes; they’ll help you keep your fleet compliant, reliable, and on the move.
You built your business through hustle and hard work. Protect it by making sure your trucks are ready when that inspector waves them over. A little extra attention today can save you thousands tomorrow and keep your wheels turning when it counts.
