Industry News

The Federal Annual Inspection: What Dealers and Commercial Carriers Need to Know

Written by Jay O'Leary, Government Relations & Compliance Specialist | Oct 16, 2025 7:12:03 PM

Even as New Hampshire transitions away from its long-standing state vehicle inspection program, one crucial fact remains: federal law still requires many commercial vehicles to undergo a Federal Annual Inspection every 12 months. This inspection, governed by the Federal Motor Carrier Safety Regulations (FMCSRs), serves as the foundation of the nation’s effort to keep commercial vehicles mechanically safe and roadworthy.

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What the Federal Annual Inspection Is
Under 49 CFR §396.17, every commercial motor vehicle (CMV) operated in interstate commerce, or certain intrastate operations that meet federal definitions, must pass a full safety inspection each year. The process ensures that trucks, buses, and trailers meet the minimum standards for safe operation as outlined in Appendix G to the FMCSRs.

The requirement applies to several categories of vehicles, including:

  • Those with a gross vehicle weight rating (GVWR), gross combination weight rating (GCWR), or actual weight of 10,001 pounds or more
  • Vehicles transporting hazardous materials requiring placards under 49 CFR Part 172
  • Passenger vehicles designed to carry more than eight passengers for hire, or more than fifteen passengers if not for hire

In short, if a vehicle is used in commerce and meets these thresholds, it must undergo and pass the federal inspection annually.

The Purpose Behind the Requirement
The intent of the Federal Annual Inspection is simple: to prevent crashes caused by vehicle defects and ensure uniform national safety standards. Federal regulators recognize that even minor mechanical failures, such as worn brakes or steering issues, can lead to catastrophic consequences when they occur on large or heavy vehicles.

By requiring consistent, documented inspections, the FMCSA helps maintain accountability among carriers, drivers, and maintenance facilities across all states.

Who Can Perform the Inspection
The inspection must be carried out by a qualified inspector, someone with the training, knowledge, or experience necessary to accurately evaluate the condition of commercial vehicles. Under 49 CFR §396.19, an inspector must understand the methods, procedures, tools, and equipment used to perform safety inspections and must be able to identify when a component fails to meet federal standards.

Qualified inspectors may include:

  • A carrier’s own maintenance employee with documented qualifications
  • A licensed dealer or commercial garage meeting FMCSA standards
  • A third-party inspection service or technician certified through a recognized training program

Importantly, if you were once a certified state inspector licensed to conduct safety inspections on the same class of vehicle you intend to inspect, you are considered qualified to perform Federal Annual Inspections on that vehicle class under FMCSA guidelines. This recognition reflects the equivalency between the knowledge and training required for state safety inspection certification and the federal qualification standards.

Motor carriers are responsible for maintaining records showing each inspector’s qualifications and the results of every inspection performed.

What the Inspection Covers
The Federal Annual Inspection is a thorough, component-by-component review of the vehicle’s safety systems. Inspectors must examine and verify the condition of each item listed in Appendix G, including:

  • Brakes: service and parking brakes, drums, rotors, hoses, linings, and warning devices
  • Steering: steering column, gear box, linkage, and power assist components
  • Lights and reflectors: headlamps, tail lamps, turn signals, clearance lamps, and reflectors
  • Tires and wheels: tread depth, inflation, and evidence of cracking or missing lugs
  • Windshield and wipers: clear visibility and proper operation
  • Coupling devices: fifth wheels, pintle hooks, and safety chains
  • Suspension and frame: springs, torque arms, bushings, cracks, and corrosion
  • Fuel and exhaust systems: leaks, secure mounting, and proper routing
  • Emergency equipment: fire extinguisher, warning triangles, and spare fuses

Each inspection must be documented using a Federal Annual Inspection Report or an equivalent form that meets FMCSA standards.

Documentation and Recordkeeping
Compliance does not end when the inspection is complete. Carriers are required to keep a copy of the inspection report for 14 months from the date it was performed. Each commercial vehicle must also display a valid inspection decal or carry a copy of the report inside the vehicle.

If the vehicle fails the inspection, the defects must be corrected before it is returned to service. Operating without a valid annual inspection can lead to citations, fines, and possible out-of-service orders.

Relationship to State Inspections
It’s important for New Hampshire dealers and repairers to understand that the repeal of the state’s annual inspection program does not affect the federal requirement for commercial vehicles. Even in the absence of a state-mandated safety inspection, commercial vehicles operating in interstate commerce, or under FMCSA authority, must still comply with the annual inspection provisions of 49 CFR §396.17.

In other words, while personal vehicles may no longer require a yearly inspection beginning in 2026, commercial motor vehicles will still need one every year under federal law.

What You Should Know
Those who sell or service commercial vehicles can play a key role in maintaining compliance. Those with qualified technicians and proper documentation may be able to perform Federal Annual Inspections for customers, providing a valuable service to fleets and carriers.

Final Thoughts
As New Hampshire navigates changes to its inspection framework, federal safety obligations remain unchanged. The Federal Annual Inspection serves as the minimum national standard for ensuring that the vehicles traveling on our roads are mechanically sound and safe to operate. For carriers, technicians, and dealers, maintaining compliance is not just a legal requirement, it’s a commitment to the safety of everyone who shares the highway.