Brake System Inspection Checklist - Safety

Vehicle & Inspector Information

Vehicle ID/Number:

Vehicle Make/Model:

Current Mileage:

Inspector Name:

Inspection Date:

Last Brake Service:

CRITICAL BRAKE SAFETY WARNING

Brake system failure is the leading cause of commercial vehicle accidents. Any item marked as "Critical Failure" must ground the vehicle immediately until repairs are completed. This inspection ensures DOT compliance and passenger safety.

Pre-Inspection Safety Checks

Initial Safety Verification

Vehicle parked on level surface with parking brake engaged CRITICAL

Engine off, key removed, and wheels properly chocked

All passengers evacuated and safety perimeter established

Visual Brake System Inspection

Brake Pedal & Controls

Brake pedal has firm feel and does not sink to floor CRITICAL

Parking brake engages properly and holds vehicle

Brake warning lights and dashboard indicators function properly

Brake Fluid System

Brake fluid level above minimum mark and clear/clean CRITICAL

No visible brake fluid leaks under vehicle or at components CRITICAL

Brake booster operation verified (vacuum or hydraulic assist)

Brake Pads, Shoes & Rotors

Front Brake Pads & Rotors

Front brake pad thickness ≥ 3mm (DOT minimum requirement) CRITICAL

Front rotors within thickness specification and not cracked CRITICAL

No uneven wear patterns or glazing on friction surfaces

Rear Brake System

Rear brake pads/shoes ≥ 2mm thickness (DOT minimum) CRITICAL

Rear rotors/drums within specification and undamaged

All brake hardware and mounting components secure

Brake Lines & Hydraulic System

Brake Lines Inspection

All brake lines free from corrosion, kinks, or damage CRITICAL

Flexible brake hoses show no cracks, bulging, or leaks CRITICAL

All brake line fittings and connections properly tightened

Air Brake System (if equipped)

Air System Pressure & Operation

Air system maintains minimum 90 psi for safe operation CRITICAL

Air compressor builds pressure to 100 psi within 45 seconds

Air tanks drained of moisture and contamination

Spring brake and service brake adjustments within limits

Brake Performance Testing

Operational Performance Tests

Vehicle stops within DOT-specified stopping distances CRITICAL

No pulling to one side during braking application CRITICAL

ABS system functional with proper warning light operation

Emergency/parking brake holds vehicle on 20% grade

Documentation & Compliance

Inspection Records & Compliance

All measurements and findings properly recorded

DOT brake system compliance verified and documented

Vehicle tagged out-of-service if critical failures found CRITICAL

Brake Inspection Notes & Findings

Use Checklist Online

Bus Brake System Safety Inspection