Top 5 FHWA Inspection Failures — And How to Stay Ahead of Them

Failing a Federal Highway Administration (FHWA) inspection is more than a compliance headache — it puts your equipment, drivers, and customers at risk. It can also lead to costly repairs, red-tagged trailers, and serious DOT penalties.

The 5 Most Common FHWA Violations

1. Inoperative Lighting Systems
   • Brake lights, side markers, and turn signals are among the most frequently cited failures.
2. Brake System Deficiencies
   • Cracked linings, out-of-adjustment slack adjusters, and contaminated components.
3. Tire Violations
   • Tread depth below minimum, sidewall damage, or mismatched sizes.
4. Suspension and Frame Cracks
   • Structural integrity issues from corrosion or wear.
5. Missing or Expired FHWA Inspection Decals
   • Failing to document or display compliance properly.

Why Fleets Fall Behind

• Lack of a structured inspection calendar
• Deferred repairs due to scheduling conflicts
• Limited access to qualified trailer techs
• Poor recordkeeping or outdated inspection logs

How to Stay Inspection-Ready

1. Adopt a Standardized Inspection Schedule
   Don’t wait for DOT enforcement to find issues. Schedule inspections every 12 months minimum, with mid-cycle checkups for high-mileage trailers.
2. Partner With a Certified Inspection Provider
   Qualified technicians ensure all FHWA criteria are met and logged correctly.
3. Digitize Inspection Records
   Paper logs get lost or outdated. Digital reporting ensures you can prove compliance at any time.
4. Train Your Team to Spot Red Flags
   Pre-trip walkarounds can catch major issues before trailers go out.

Build Safety, Compliance, and Trust

Well-maintained trailers reflect the quality of your operation. Staying ahead of FHWA inspections means safer roads, fewer fines, and more reliable freight performance.

Bottom Line: Compliance isn’t just a legal requirement — it’s a competitive advantage.