49 CFR Part 396 — Inspection, Repair, and Maintenance

PART 396—INSPECTION, REPAIR, AND MAINTENANCE Authority: 49 U.S.C. 504, 31133, 31136, 31151, 31502; sec. 32934, Pub. L. 112-141, 126 Stat. 405, 830; sec. 5524, Pub. L. 114-94, 129 Stat. 1312, 1560; and 49 CFR 1.87. Source: 44 FR 38526, July 2, 1979, unless otherwise noted. Editorial Note: Nomenclature changes to part 396 appear at 66 FR 49874, Oct. 1, 2001. § 396.1 Scope. (a) Every motor carrier, its officers, drivers, agents, representatives, and employees directly concerned with the inspection or maintenance of commercial motor vehicles must be knowledgeable of and comply with the rules of this part. (b) Every intermodal equipment provider, its officers, agents, representatives, and employees directly concerned with the inspection or maintenance of intermodal equipment interchanged or offered for interchange to motor carriers must be knowledgeable of and comply with the rules of this part. (c) This part does not apply to “covered farm vehicles,” as defined in 49 CFR 390.5, or to the drivers of such vehicles. (d) The rules in this part do not apply to “pipeline welding trucks” as defined in 49 CFR 390.38(b). [73 FR 76823, Dec. 17, 2008, as amended at 78 FR 16195, Mar. 14, 2013; 81 FR 47722, July 22, 2016] § 396.3 Inspection, repair, and maintenance. (a) General. (1) Parts and accessories shall be in safe and proper operating condition at all times. These include those specified in part 393 of this subchapter and any additional parts and accessories which may affect safety of operation, including but not limited to, frame and frame assemblies, suspension systems, axles and attaching parts, wheels and rims, and steering systems. (2) Pushout windows, emergency doors, and emergency door marking lights in buses shall be inspected at least every 90 days. (b) Required records. (1) An identification of the vehicle including company number, if so marked, make, serial number, and year. In addition, if the motor vehicle is not owned by the motor carrier, the record shall identify the name of the person furnishing the vehicle; (2) A means to indicate the nature and due date of the various inspection and maintenance operations to be performed; (3) A record of inspection, repairs, and maintenance indicating their date and nature; and (4) A record of tests conducted on pushout windows, emergency doors, and emergency door marking lights on buses. (c) Record retention. [44 FR 38526, July 2, 1979, as amended at 48 FR 55868, Dec. 16, 1983; 53 FR 18058, May 19, 1988; 59 FR 8753, Feb. 23, 1994; 59 FR 60324, Nov. 23, 1994; 73 FR 75824, Dec. 17, 2008; 91 FR 45662, July 21, 2026] § 396.5 Lubrication. Every motor carrier shall ensure that each motor vehicle subject to its control is— (a) Properly lubricated; and (b) Free of oil and grease leaks. § 396.7 Unsafe operations forbidden. (a) General. (b) Exemption. § 396.9 Inspection of motor vehicles and intermodal equipment in operation. (a) Personnel authorized to perform inspections. (b) Prescribed inspection report. (c) Motor vehicles and intermodal equipment declared “out-of-service.” (2) No motor carrier or intermodal equipment provider shall require or permit any person to operate nor shall any person operate any motor vehicle or intermodal equipment declared and marked “out-of-service” until all repairs required by the “out-of-service notice” have been satisfactorily completed. The term operate (3) No person shall remove the “Out-of-Service Vehicle” sticker from any motor vehicle or intermodal equipment prior to completion of all repairs required by the “out-of-service notice.” (d) Motor carrier or intermodal equipment provider disposition. (2) Motor carriers and intermodal equipment providers shall examine the report. Violations or defects noted thereon shall be corrected in accordance with § 396.11(a)(3). Repairs of items of intermodal equipment placed out-of-service are also to be documented in the maintenance records for such equipment. (3) Within 15 days following the date of the inspection, the motor carrier or intermodal equipment provider shall— (i) Certify that all violations noted have been corrected by completing the “Signature of Carrier/Intermodal Equipment Provider Official, Title, and Date Signed” portions of the form; and (ii) If requested by the issuing State agency, return the completed roadside inspection form to the issuing State agency at the address indicated on the form and, in all instances, retain a copy at the motor carrier's principal place of business, at the intermodal equipment provider's principal place of business, or where the vehicle is housed for 12 months from the date of the inspection, in accordance with paragraph (d)(3)(i) of this section. [73 FR 76824, Dec. 17, 2008, as amended at 75 FR 17252, Apr. 5, 2010; 77 FR 28451, May 14, 2012; 78 FR 58485, Sept. 24, 2013; 81 FR 47731, July 22, 2016; 88 FR 80193, Nov. 17, 2023; 91 FR 37056, June 22, 2026] § 396.11 Driver vehicle inspection report(s). (a) Equipment provided by motor carrier. Report required. (i) Service brakes including trailer brake connections; (ii) Parking brake; (iii) Steering mechanism; (iv) Lighting devices and reflectors; (v) Tires; (vi) Horn; (vii) Windshield wipers; (viii) Rear vision mirrors; (ix) Coupling devices; (x) Wheels and rims; (xi) Emergency equipment. (2) Report content. (ii) The driver must sign the report. On two-driver operations, only one driver needs to sign the driver vehicle inspection report, provided both drivers agree as to the defects or deficiencies identified. (3) Corrective action. (ii) Every motor carrier or its agent shall certify on the driver vehicle inspection report which lists any defect or deficiency that the defect or deficiency has been repaired or that repair is unnecessary before the vehicle is operated again. (4) Retention period for reports. (5) Exceptions. (6) Electronic reporting. (b) Equipment provided by intermodal equipment provider. Report required. (i) Brakes; (ii) Lighting devices, lamps, markers, and conspicuity marking material; (iii) Wheels, rims, lugs, tires; (iv) Air line connections, hoses, and couplers; (v) King pin upper coupling device; (vi) Rails or support frames; (vii) Tie down bolsters; (viii) Locking pins, clevises, clamps, or hooks; (ix) Sliders or sliding frame lock. (2) Report content. (ii) Motor carrier's USDOT number; intermodal equipment provider's USDOT number, and a unique identifying number for the item of intermodal equipment. (iii) Date and time the report was submitted. (iv) All damage, defects, or deficiencies of the intermodal equipment reported to the equipment provider and discovered by, or reported to, the motor carrier or its driver which would (A) Affect the safety of operation of the intermodal equipment, or (B) Result in its mechanical breakdown while transported on public roads. (v) The signature of the driver who prepared the report. (3) Corrective action. (ii) Each intermodal equipment provider or its agent must certify on the original driver's report which lists any damage, defects, or deficiencies of the intermodal equipment that the reported damage, defects, or deficiencies have been repaired, or that repair is unnecessary, before the vehicle is operated again. (4) Retention period for reports. (5) Electronic reporting. [44 FR 38526, July 2, 1979, as amended at 45 FR 46425, July 10, 1980; 53 FR 18058, May 19, 1988; 59 FR 8753, Feb. 23, 1994; 63 FR 33279, June 18, 1998; 73 FR 76824, Dec. 17, 2008; 74 FR 68709, Dec. 29, 2009; 77 FR 34852, June 12, 2012; 77 FR 59828, Oct. 1, 2012; 78 FR 58485, Sept. 24, 2013; 79 FR 75449, Dec. 18, 2014; 83 FR 16227, Apr. 16, 2018; 85 FR 50793, Aug. 18, 2020; 91 FR 7896, Feb. 19, 2026] § 396.12 Procedures for intermodal equipment providers to accept reports required by § 390.42(b) of this chapter. (a) System for reports. (1) Affect the safety of operation of the intermodal equipment, or (2) Result in its mechanical breakdown while transported on public roads. (b) Report content. (1) Name of the motor carrier responsible for the operation of the intermodal equipment at the time the damage, defects, or deficiencies were discovered by, or reported to, the driver. (2) Motor carrier's USDOT number; intermodal equipment provider's USDOT number, and a unique identifying number for the item of intermodal equipment. (3) Date and time the report was submitted. (4) All damage, defects, or deficiencies of the intermodal equipment must be reported to the equipment provider by the motor carrier or its driver. If no defect or deficiency in the intermodal equipment is discovered by or reported to the driver, no written report is required. (5) The signature of the driver who prepared the report. (c) Corrective action. (2) Each intermodal equipment provider or its agent must certify on the original driver's report which lists any damage, defects, or deficiencies of the intermodal equipment that the reported damage, defects, or deficiencies have been repaired, or that repair is unnecessary, before the vehicle is operated again. (d) Retention period for reports. [73 FR 76824, Dec. 17, 2008, as amended at 74 FR 68709, Dec. 29, 2009; 77 FR 34852, June 12, 2012; 83 FR 16227, Apr. 16, 2018] § 396.13 Driver inspection. Before driving a motor vehicle, the driver shall: (a) Be satisfied that the motor vehicle is in safe operating condition; (b) Review the last driver vehicle inspection report if required by § 396.11(a)(2)(i); and (c) Sign the report to acknowledge that the driver has reviewed it and that there is a certification that the required repairs have been performed. The signature requirement does not apply to listed defects on a towed unit which is no longer part of the vehicle combination. (d) The reports required by this section may be created and maintained in electronic format, in accordance with 49 CFR 390.32. [44 FR 76526, Dec. 27, 1979, as amended at 48 FR 55868, Dec. 16, 1983; 63 FR 33280, June 18, 1998; 85 FR 50793, Aug. 18, 2020; 91 FR 7896, Feb. 19, 2026] § 396.15 Driveaway-towaway operations and inspections. (a) General. (b) Pre-trip inspection. (1) The tow-bar or saddle-mount connections are properly secured to the towed and towing vehicle; (2) They function adequately without cramping or binding of any of the parts; and (3) The towed motor vehicle follows substantially in the path of the towing vehicle without whipping or swerving. (c) Post-trip inspection. [44 FR 38526, July 2, 1979, as amended at 53 FR 49410, Dec. 7, 1988; 53 FR 49968, Dec. 12, 1988; 78 FR 58485, Sept. 24, 2013; 84 FR 51435, Sept. 30, 2019] § 396.17 Periodic inspection. (a) Every commercial motor vehicle must be inspected as required by this section. The inspection must include, at a minimum, the parts and accessories set forth in appendix A to this part. The term commercial motor vehicle (b) Except as provided in § 396.23 and this paragraph, motor carriers must inspect or cause to be inspected all motor vehicles subject to their control. Intermodal equipment providers must inspect or cause to be inspected intermodal equipment that is interchanged or intended for interchange to motor carriers in intermodal transportation. (c) A motor carrier must not use a commercial motor vehicle, and an intermodal equipment provider must not tender equipment to a motor carrier for interchange, unless each component identified in appendix A to this part has passed an inspection in accordance with the terms of this section at least once during the preceding 12 months and documentation of such inspection is on the vehicle. The documentation may be: (1) The inspection report prepared in accordance with § 396.21(a), or (2) Other forms of documentation, based on the inspection report (e.g., sticker or decal), which contains the following information: (i) The date of inspection; (ii) Name and address of the motor carrier, intermodal equipment provider, or other entity where the inspection report is maintained; (iii) Information uniquely identifying the vehicle inspected if not clearly marked on the motor vehicle; and (iv) A certification that the vehicle has passed an inspection in accordance with § 396.17. (d) A motor carrier may perform the required annual inspection for vehicles under the carrier's control which are not subject to an inspection under § 396.23(a)(1). An intermodal equipment provider may perform the required annual inspection for intermodal equipment interchanged or intended for interchange to motor carriers that are not subject to an inspection under § 396.23(a)(1). (e) In lieu of the self-inspection provided for in paragraph (d) of this section, a motor carrier or intermodal equipment provider responsible for the inspection may choose to have a commercial garage, fleet leasing company, truck stop, or other similar commercial business perform the inspection as its agent, provided that business operates and maintains facilities appropriate for commercial vehicle inspections and it employs qualified inspectors, as required by § 396.19. (f) Vehicles passing periodic inspections performed under the auspices of any State government or equivalent jurisdiction in the Canadian Provinces, the Yukon Territory, and Mexico, meeting the minimum standards contained in appendix A to this part, will be considered to have met the requirements of an annual inspection for a period of 12 months commencing from the last day of the month in which the inspection was performed. (g) It is the responsibility of the motor carrier or intermodal equipment provider to ensure that all parts and accessories on commercial motor vehicles intended for use in interstate commerce for which they are responsible are maintained at, or promptly repaired to, the minimum standards set forth in appendix A to this part. (h) Failure to perform properly the annual inspection required by this section shall cause the motor carrier or intermodal equipment provider to be subject to the penalty provisions of 49 U.S.C. 521(b). [73 FR 76825, Dec. 17, 2008, as amended at 81 FR 47732, July 22, 2016; 83 FR 22881, May 17, 2018; 86 FR 57077, Oct. 14, 2021] § 396.19 Inspector qualifications. (a) Motor carriers and intermodal equipment providers must ensure that individuals performing annual inspections under § 396.17(d) or (e) are qualified as follows: (1) Understand the inspection criteria set forth in part 393 and appendix A to this part and can identify defective components; (2) Are knowledgeable of and have mastered the methods, procedures, tools and equipment used when performing an inspection; and (3) Are capable of performing an inspection by reason of experience, training, or both as follows: (i) Successfully completed a Federal-or State-sponsored training program or have a certificate from a State or Canadian Province that qualifies the individuals to perform commercial motor vehicle safety inspections, or (ii) Have a combination of training or experience totaling at least 1 year. Such training or experience may consist of: (A) Participation in a commercial motor vehicle manufacturer-sponsored training program or similar commercial training program designed to train students in commercial motor vehicle operation and maintenance; (B) Experience as a mechanic or inspector in a motor carrier or intermodal equipment maintenance program; (C) Experience as a mechanic or inspector in commercial motor vehicle maintenance at a commercial garage, fleet leasing company, or similar facility; or (D) Experience as a commercial motor vehicle inspector for a State, Provincial or Federal government. (b) Motor carriers and intermodal equipment providers must retain evidence of that individual's qualifications under this section. They must retain this evidence for the period during which that individual is performing annual motor vehicle inspections for the motor carrier or intermodal equipment provider, and for one year thereafter. However, motor carriers and intermodal equipment providers do not have to maintain documentation of inspector qualifications for those inspections performed as part of a State periodic inspection program. [73 FR 76825, Dec. 17, 2008, as amended at 81 FR 47732, July 22, 2016; 86 FR 57077, Oct. 14, 2021] § 396.21 Periodic inspection recordkeeping requirements. (a) The qualified inspector performing the inspection shall prepare a report that: (1) Identifies the individual performing the inspection; (2) Identifies the motor carrier operating the vehicle or intermodal equipment provider intending to interchange the vehicle to a motor carrier; (3) Identifies the date of the inspection; (4) Identifies the vehicle inspected; (5) Identifies the vehicle components inspected and describes the results of the inspection, including the identification of those components not meeting the minimum standards set forth in appendix A to this part; and (6) Certifies the accuracy and completeness of the inspection as complying with all the requirements of this section. (b)(1) The original or a copy of the inspection report shall be retained by the motor carrier, intermodal equipment provider, or other entity that is responsible for the inspection for a period of fourteen months from the date of the inspection report. The original or a copy of the inspection report must be retained where the vehicle is either housed or maintained. (2) The original or a copy of the inspection report must be available for inspection upon demand of an authorized Federal, State or local official. (3) Exception. [73 FR 76825, Dec. 17, 2008, as amended at 86 FR 57077, Oct. 14, 2021] § 396.23 Equivalent to periodic inspection. (a)(1) If a commercial motor vehicle is subject to a mandatory inspection program that is determined by the Administrator to be as effective as § 396.17, the motor carrier or intermodal equipment provider must meet the requirement of § 396.17 through that inspection program. Commercial motor vehicle inspections may be conducted by government personnel, at commercial facilities authorized by a State government or equivalent jurisdiction in the Canadian Provinces, the Yukon Territory, or Mexico, or by the motor carrier or intermodal equipment provider itself under the auspices of a self-inspection program authorized by a State government or equivalent jurisdiction in the Canadian Provinces, the Yukon Territory, or Mexico. (2) Should FMCSA determine that an inspection program, in whole or in part, is not as effective as § 396.17, the motor carrier or intermodal equipment provider must ensure that the periodic inspection required by § 396.17 is performed on all commercial motor vehicles under its control in a manner specified in § 396.17. (b) [Reserved] [83 FR 22881, May 17, 2018] § 396.25 Qualifications of brake inspectors. (a) Motor carriers and intermodal equipment providers must ensure that all inspections, maintenance, repairs or service to the brakes of its commercial motor vehicles, are performed in compliance with the requirements of this section. (b) For purposes of this section, brake inspector (c) No motor carrier or intermodal equipment provider may require or permit any employee who does not meet the minimum brake inspector qualifications of paragraph (d) of this section to be responsible for the inspection, maintenance, service or repairs of any brakes on its commercial motor vehicles. (d) The motor carrier or intermodal equipment provider must ensure that each brake inspector is qualified as follows: (1) Understands the brake service or inspection task to be accomplished and can perform that task; and (2) Is knowledgeable of and has mastered the methods, procedures, tools and equipment used when performing an assigned brake service or inspection task; and (3) Is capable of performing the assigned brake service or inspection by reason of experience, training, or both as follows: (i) Has successfully completed an apprenticeship program sponsored by a State, a Canadian Province, a Federal agency or a labor union, or a training program approved by a State, Provincial or Federal agency, or has a certificate from a State or Canadian Province that qualifies the person to perform the assigned brake service or inspection task (including passage of Commercial Driver's License air brake tests in the case of a brake inspection); or (ii) Has brake-related training or experience or a combination thereof totaling at least one year. Such training or experience may consist of: (A) Participation in a training program sponsored by a brake or vehicle manufacturer or similar commercial training program designed to train students in brake maintenance or inspection similar to the assigned brake service or inspection tasks; or (B) Experience performing brake maintenance or inspection similar to the assigned brake service or inspection task in a motor carrier or intermodal equipment provider maintenance program; or (C) Experience performing brake maintenance or inspection similar to the assigned brake service or inspection task at a commercial garage, fleet leasing company, or similar facility. (e) No motor carrier or intermodal equipment provider may employ any person as a brake inspector unless the evidence of the inspector's qualifications, required under this section, is maintained by the motor carrier or intermodal equipment provider at its principal place of business, or at the location at which the brake inspector is employed. The evidence must be maintained for the period during which the brake inspector is employed in that capacity and for one year thereafter. However, motor carriers and intermodal equipment providers do not have to maintain evidence of qualifications to inspect air brake systems for such inspections performed by persons who have passed the air brake knowledge and skills test for a Commercial Driver's License. [73 FR 76825, Dec. 17, 2008] Appendix A to Part 396—Minimum Periodic Inspection Standards A vehicle does not pass an inspection if it has one of the following defects or deficiencies: 1. Brake System. a. Service brakes. (2) Missing or broken mechanical components including: shoes, lining, pads, springs, anchor pins, spiders, cam rollers, push-rods, and air chamber mounting bolts. (3) Loose brake components including air chambers, spiders, and cam shaft support brackets. (4) Audible air leak at brake chamber (Example-ruptured diaphragm, loose chamber clamp, etc.). (5) Readjustment limits. (a) The maximum pushrod stroke must not be greater than the values given in the tables below and at § 393.47(e). Any brake stroke exceeding the readjustment limit will be rejected. Stroke must be measured with engine off and reservoir pressure of 80 to 90 psi with brakes fully applied. Clamp-Type Brake Chambers Type Outside diameter Brake readjustment limit: standard stroke chamber Brake readjustment limit: long stroke chamber 6 4 1 2 1 1 4 9 5 1 4 1 3 8 12 5 11 16 1 3 8 1 3 4 16 6 3 8 1 3 4 2 in. (50.8 mm). 20 6 25 32 1 3 4 2 in. (50.8 mm). 1 2 1 24 7 7 32 1 3 4 2 in. (50.8 mm). 1 2 2 30 8 3 32 2 in. (50.8 mm) 2 1 2 36 9 in. (229 mm) 2 1 2 1 2 Bendix DD-3 Brake Chambers Type Outside diameter Brake readjustment limit 30 8 1 8 2 1 4 Bolt-Type Brake Chambers Type Outside diameter Brake readjustment limit A 6 15 16 1 3 8 B 9 3 16 1 3 4 C 8 1 16 1 3 4 D 5 1 4 1 1 4 E 6 3 16 1 3 8 F 11 in. (279 mm) 2 1 4 G 9 7 8 2 in. (50.8 mm). Rotochamber-Type Brake Chambers Type Outside diameter Brake readjustment limit 9 4 9 32 1 1 2 12 4 13 16 1 1 2 16 5 13 32 2 in. (50.8 mm). 20 5 15 16 2 in. (50.8 mm). 24 6 13 32 2 in. (50.8 mm). 30 7 1 16 2 1 4 36 7 5 8 2 3 4 50 8 7 8 3 in. (76.2 mm). (b) For actuator types not listed in these tables, the pushrod stroke must not be greater than 80 percent of the rated stroke marked on the actuator by the actuator manufacturer, or greater than the readjustment limit marked on the actuator by the actuator manufacturer. (6) Brake linings or pads. (a) Lining or pad is not firmly attached to the shoe; (b) Saturated with oil, grease, or brake fluid; or (c) Non-steering axles: Lining with a thickness less than 1/4 1/16 1/8 (d) Steering axles: Lining with a thickness less than 1/4 1/8 1/16 (7) Missing brake on any axle required to have brakes. (8) Mismatch across any power unit steering axle of: (a) Air chamber sizes. (b) Slack adjuster length. Wedge Brake Data—Movement of the scribe mark on the lining shall not exceed 1/16 inch. b. Parking Brake System. c. Brake Drums or Rotors. (1) With any external crack or cracks that open upon brake application (do not confuse short hairline heat check cracks with flexural cracks). (2) Any portion of the drum or rotor missing or in danger of falling away. d. Brake Hose. (1) Hose with any damage extending through the outer reinforcement ply. (Rubber impregnated fabric cover is not a reinforcement ply). (Thermoplastic nylon may have braid reinforcement or color difference between cover and inner tube. Exposure of second color is cause for rejection. (2) Bulge or swelling when air pressure is applied. (3) Any audible leaks. (4) Two hoses improperly joined (such as a splice made by sliding the hose ends over a piece of tubing and clamping the hose to the tube). (5) Air hose cracked, broken or crimped. e. Brake Tubing. (1) Any audible leak. (2) Tubing cracked, damaged by heat, broken or crimped. f. Low Pressure Warning Device 1/2 g. Tractor Protection Valve. h. Air Compressor. (1) Compressor drive belts in condition of impending or probable failure. (2) Loose compressor mounting bolts. (3) Cracked, broken or loose pulley. (4) Cracked or broken mounting brackets, braces or adapters. i. Electric Brakes. (1) Absence of braking action on any wheel required to have brakes. (2) Missing or inoperable breakaway braking device. j. Hydraulic Brakes. (Including Power Assist Over Hydraulic and Engine Drive Hydraulic Booster). (1) Master cylinder less than 1/4 (2) No pedal reserve with engine running except by pumping pedal. (3) Power assist unit fails to operate. (4) Seeping or swelling brake hose(s) under application of pressure. (5) Missing or inoperative check valve. (6) Has any visually observed leaking hydraulic fluid in the brake system. (7) Has hydraulic hose(s) abraded (chafed) through outer cover-to-fabric layer. (8) Fluid lines or connections leaking, restricted, crimped, cracked or broken. (9) Brake failure or low fluid warning light on and/or inoperative. k. Vacuum Systems. (1) Has insufficient vacuum reserve to permit one full brake application after engine is shut off. (2) Has vacuum hose(s) or line(s) restricted, abraded (chafed) through outer cover to cord ply, crimped, cracked, broken or has collapse of vacuum hose(s) when vacuum is applied. (3) Lacks an operative low-vacuum warning device as required. l. Antilock Brake System 1 2 3 (1) Missing ABS malfunction indicator components ( i.e., (2) ABS malfunction indicator that does not illuminate when power is first applied to the ABS controller (ECU) during initial power up. (3) ABS malfunction indicator that stays illuminated while power is continuously applied to the ABS controller (ECU). (4) ABS malfunction indicator lamp on a trailer or dolly does not cycle when electrical power is applied (a) only to the vehicle's constant ABS power circuit, or (b) only to the vehicle's stop lamp circuit. (5) With its brakes released and its ignition switch in the normal run position, power unit does not provide continuous electrical power to the ABS on any air-braked vehicle it is equipped to tow. (6) Other missing or inoperative ABS components. 1 2 3 m. Automatic Brake Adjusters (1) Failure to maintain a brake within the brake stroke limit specified by the vehicle manufacturer. (2) Any automatic brake adjuster that has been replaced with a manual adjuster. (3) Damaged, loose, or missing components. (4) Any brake that is found to be out of adjustment on initial inspection must be evaluated to determine why the automatic brake adjuster is not functioning properly and the problem must be corrected in order for the vehicle to pass the inspection. It is not acceptable to manually adjust automatic brake adjusters without first correcting the underlying problem. For example, there may be other components within the braking system that are distressed or out of specification ( i.e., 2. Coupling devices. a. Fifth Wheels. (1) Mounting to frame. (a) Any fasteners missing or ineffective. (b) Any movement between mounting components. (c) Any mounting angle iron cracked or broken. (2) Mounting plates and pivot brackets. (a) Any fasteners missing or ineffective. (b) Any welds or parent metal cracked. (c) More than 3/8 (d) Pivot bracket pin missing or not secured. (3) Sliders. (a) Any latching fasteners missing or ineffective. (b) Any fore or aft stop missing or not securely attached. (c) Movement more than 3/8 (d) Any slider component cracked in parent metal or weld. (4) Lower coupler. (a) Horizontal movement between the upper and lower fifth wheel halves exceeds 1/2 (b) Operating handle not in closed or locked position. (c) Kingpin not properly engaged. (d) Separation between upper and lower coupler allowing light to show through from side to side. (e) Cracks in the fifth wheel plate. Exceptions: (f) Locking mechanism parts missing, broken, or deformed to the extent the kingpin is not securely held. b. Pintle Hooks. (1) Mounting to frame. (a) Any missing or ineffective fasteners (a fastener is not considered missing if there is an empty hole in the device but no corresponding hole in the frame or vice versa). (b) Mounting surface cracks extending from point of attachment (e.g., cracks in the frame at mounting bolt holes). (c) Loose mounting. (d) Frame cross member providing pintle hook attachment cracked. (2) Integrity. (a) Cracks anywhere in pintle hook assembly. (b) Any welded repairs to the pintle hook. (c) Any part of the horn section reduced by more than 20%. (d) Latch insecure. c. Drawbar/Towbar Eye. (1) Mounting. (a) Any cracks in attachment welds. (b) Any missing or ineffective fasteners. (2) Integrity. (a) Any cracks. (b) Any part of the eye reduced by more than 20%. d. Drawbar/Towbar Tongue. (1) Slider (power or manual). (a) Ineffective latching mechanism (b) Missing or ineffective stop. (c) Movement of more than 1/4 (d) Any leaking, air or hydraulic cylinders, hoses, or chambers (other than slight oil weeping normal with hydraulic seals). (2) Integrity. (a) Any cracks. (b) Movement of 1/4 e. Safety Devices. (1) Safety devices missing. (2) Unattached or incapable of secure attachment. (3) Chains and hooks. (a) Worn to the extent of a measurable reduction in link cross section. (b) Improper repairs including welding, wire, small bolts, rope and tape. (4) Cable. (a) Kinked or broken cable strands. (b) Improper clamps or clamping. f. Saddle-Mounts. (1) Method of attachment. (a) Any missing or ineffective fasteners. (b) Loose mountings. (c) Any cracks or breaks in a stress or load bearing member. (d) Horizontal movement between upper and lower saddle-mount halves exceeds 1/4 3. Exhaust System. a. Any exhaust system determined to be leaking at a point forward of or directly below the driver/sleeper compartment. b. A bus exhaust system leaking or discharging to the atmosphere: (1) Gasoline powered—excess of 6 inches forward of the rearmost part of the bus. (2) Other than gasoline powered—in excess of 15 inches forward of the rearmost part of the bus. (3) Other than gasoline powered—forward of a door or window designed to be opened. (exception: Emergency exits). c. No part of the exhaust system of any motor vehicle shall be so located as would be likely to result in burning, charring, or damaging the electrical wiring, the fuel supply, or any combustible part of the motor vehicle. 4. Fuel System. a. A fuel system with a visable leak at any point. b. A fuel tank filler cap missing. c. A fuel tank not securely attached to the motor vehicle by reason of loose, broken or missing mounting bolts or brackets (some fuel tanks use springs or rubber bushings to permit movement). 5. Lighting Devices. 6. Safe Loading. a. Part(s) of vehicle or condition of loading such that the spare tire or any part of the load or dunnage can fall onto the roadway. b. Protection Against Shifting Cargo—Any vehicle without a front-end structure or equivalent device as required. c. Container securement devices on intermodal equipment—All devices used to secure an intermodal container to a chassis, including rails or support frames, tiedown bolsters, locking pins, clevises, clamps, and hooks that are cracked, broken, loose, or missing. 7. Steering Mechanism. a. Steering Wheel Free Play (on vehicles equipped with power steering the engine must be running). Steering wheel diameter Manual steering system Power steering system 16″ 2″ 4 1 2 18″ 2 1 4 4 3 4 20″ 2 1 2 5 1 4 22″ 2 3 4 5 3 4 b. Steering Column. (1) Any absence or looseness of U-bolt(s) or positioning part(s). (2) Worn, faulty or obviously repair welded universal joint(s). (3) Steering wheel not properly secured. c. Front Axle Beam and All Steering Components Other Than Steering Column. (1) Any crack(s). (2) Any obvious welded repair(s). d. Steering Gear Box. (1) Any mounting bolt(s) loose or missing. (2) Any crack(s) in gear box or mounting brackets. e. Pitman Arm. f. Power Steering. g. Ball and Socket Joints. (1) Any movement under steering load of a stud nut. (2) Any motion, other than rotational, between any linkage member and its attachment point of more than 1/4 h. Tie Rods and Drag Links. (1) Loose clamp(s) or clamp bolt(s) on tie rods or drag links. (2) Any looseness in any threaded joint. i. Nuts. j. Steering System. 8. Suspension. a. Any U-bolt(s), spring hanger(s), or other axle positioning part(s) cracked, broken, loose or missing resulting in shifting of an axle from its normal position. (After a turn, lateral axle displacement is normal with some suspensions. Forward or rearward operation in a straight line will cause the axle to return to alignment). b. Spring Assembly. (1) Any leaves in a leaf spring assembly broken or missing. (2) Any broken main leaf in a leaf spring assembly. (Includes assembly with more than one main spring). (3) Coil spring broken. (4) Rubber spring missing. (5) One or more leaves displaced in a manner that could result in contact with a tire, rim, brake drum or frame. (6) Broken torsion bar spring in a torsion bar suspension. (7) Deflated air suspension, i.e., system failure, leak, etc. c. Torque, Radius or Tracking Components. 9. Frame. a. Frame Members. (1) Any cracked, broken, loose, or sagging frame member. (2) Any loose or missing fasteners including fasteners attaching functional component such as engine, transmission, steering gear, suspension, body parts, and fifth wheel. b. Tire and Wheel Clearance. c. (1) Adjustable Axle Assemblies (Sliding Subframes). 10. Tires. a. Any tire on any steering axle of a power unit. (1) With less than 4/32 (2) Has body ply or belt material exposed through the tread or sidewall. (3) Has any tread or sidewall separation. (4) Has a cut where the ply or belt material is exposed. (5) Labeled “Not for Highway Use” or displaying other marking which would exclude use on steering axle. (6) A tube-type radial tire without radial tube stem markings. These markings include a red band around the tube stem, the word “radial” embossed in metal stems, or the word “radial” molded in rubber stems. (7) Mixing bias and radial tires on the same axle. (8) Tire flap protrudes through valve slot in rim and touches stem. (9) Regrooved tire except motor vehicles used solely in urban or suburban service (see exception in § 393.75(e). (10) Boot, blowout patch or other ply repair. (11) Weight carried exceeds tire load limit. This includes overloaded tire resulting from low air pressure. (12) Tire is flat or has noticeable (e.g., can be heard or felt) leak. (13) Any bus equipped with recapped or retreaded tire(s). (14) So mounted or inflated that it comes in contact with any part of the vehicle. b. All tires other than those found on the steering axle of a power unit: (1) Weight carried exceeds tire load limit. This includes overloaded tire resulting from low air pressure. (2) Tire is flat or has noticeable (e.g., can be heard or felt) leak. (3) Has body ply or belt material exposed through the tread or sidewall. (4) Has any tread or sidewall separation. (5) Has a cut where ply or belt material is exposed. (6) So mounted or inflated that it comes in contact with any part of the vehicle. (This includes a tire that contacts its mate.) (7) Is marked “Not for highway use” or otherwise marked and having like meaning. (8) With less than 2/32 c. Installation of speed-restricted tires unless specifically designated by motor carrier. 11. Wheels and Rims. a. Lock or Side Ring. b. Wheels and rims. c. Fasteners (both spoke and disc wheels). d. Welds. (1) Any cracks in welds attaching disc wheel disc to rim. (2) Any crack in welds attaching tubeless demountable rim to adapter. (3) Any welded repair on aluminum wheel(s) on a steering axle. (4) Any welded repair other than disc to rim attachment on steel disc wheel(s) mounted on the steering axle. 12. Windshield Glazing. 1/4 3/4 13. Windshield Wipers. 14. Motorcoach Seats. a. Any passenger seat that is not securely fastened to the vehicle structure. b. [Reserved] 15. Rear Impact Guard. a. Trailers and semitrailers with a GVWR of 4,536 kg (10,001 lbs.) or more, manufactured on or after January 26, 1998 (see exceptions in § 393.86(a)(1) of this subchapter). (1) Missing guard. (2) Guard is not securely attached to trailer, including broken or missing fasteners, any welds or parent metal cracked, or other damage that compromises secure attachment of the guard. (3) Guard horizontal member does not extend to within 100 mm (4 inches) of each, or extends beyond either, side extremity of the vehicle. (4) Guard horizontal member is more than 560 mm (22 inches) above the ground. (5) Guard horizontal member is more than 305 mm (12 inches) forward of the rear extremity of the vehicle. (6) Guard horizontal member does not have a cross sectional vertical height of at least 100 mm (4 inches) across its entire width. b. Commercial motor vehicles manufactured after December 31, 1952 (except trailers and semitrailers manufactured on or after January 26, 1998) (see exceptions in § 393.86(b)(1) and 393.86(b)(3) of this subchapter). (1) Missing guard. (2) Guard is not securely attached to trailer by bolts, welding, or other comparable means. (3) Guard horizontal member is more than 762 mm (30 inches) above the ground. (4) Guard horizontal member does not extend to within 457 mm (18 inches) of each side extremity of the vehicle. (5) Guard horizontal member is more than 610 mm (24 inches) forward of the rear extremity of the vehicle. [53 FR 49411, Dec. 7, 1988; 53 FR 49968, Dec. 12, 1988, as amended at 66 FR 49875, Oct. 1, 2001; 73 FR 76827, Dec. 17, 2008; 77 FR 46639, Aug. 8, 2012; 77 FR 59829, Oct. 1, 2012; 78 FR 58486, Sept. 24, 2013; 81 FR 47732, July 22, 2016; 81 FR 60634, Sept. 2, 2016. Redesignated and amended at 86 FR 57068, 57077, Oct. 14, 2021; 86 FR 62111, Nov. 9, 2021; 87 FR 59037, Sept. 29, 2022]

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