State Inspection

Perform a state safety inspection on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine, checking all required safety systems and components per state inspection requirements.

Warnings

Tools required

Preparation

1. Park vehicle on level, solid surface in well-lit inspection area
2. Verify vehicle registration and VIN match
3. Check that odometer is functional and record mileage
4. Ensure engine is cold enough to safely inspect exhaust system
5. Place wheel chocks behind rear wheels

Procedure

1. 1

   Lighting and Electrical System Check
   Check all exterior lights for proper operation: headlights (low and high beam), turn signals (front and rear), brake lights, reverse lights, license plate light, and hazard lights. Verify headlight aim is within specification. Test horn operation. Check that all lights have proper colored lenses with no cracks or damage.
2. 2

   Windshield and Glass Inspection
   Inspect windshield for cracks, chips, or damage in driver's field of view. Check that all windows operate properly if power windows are equipped. Test windshield wipers for proper operation and blade condition. Verify windshield washer system functions and sprays correctly. Inspect all mirrors for secure mounting and proper adjustment capability.
3. 3

   Tire and Wheel Inspection
   Measure tread depth on all four tires using tread depth gauge - minimum tread depth is typically 2/32 inch but verify state requirement. Check for uneven wear, bulges, cuts, or other damage. Verify all lug nuts are present and tight. Check tire sidewalls for proper size markings and DOT certification. Inspect wheels for cracks or damage.
4. 4

   Brake System Check
   Test brake pedal for firm feel with engine running - pedal should not sink to floor. Check parking brake holds vehicle on incline or against light acceleration. Inspect brake fluid level in master cylinder reservoir - should be between MIN and MAX marks. Verify brake warning light illuminates with key on, engine off, and extinguishes when engine starts. Test brake operation during road test if permitted by inspection facility.
5. 5

   Steering and Suspension Inspection
   Check steering wheel for excessive play - should be less than 2 inches of free play at rim. Inspect power steering fluid level and condition. Safely raise front of vehicle and support on jack stands. Check for loose or worn steering linkage components by attempting to move wheels side-to-side with hands at 3 and 9 o'clock positions. Inspect ball joints and tie rod ends for excessive play or torn boots.
6. 6

   Front Suspension and CV Components
   With front of vehicle raised, inspect the solid front axle U-joints, axle shaft seals, and ball joint boots for damage, wear, or grease leakage. Check front differential for fluid leaks at housing, axle seals, and pinion seal. Inspect front shock absorbers for fluid leaks and secure mounting. Check front leaf springs (1994-2002) or coil springs (2003+) for cracks, broken leaves, or damage. Verify sway bar links and bushings are intact and secure.
7. 7

   Undercarriage and Exhaust Inspection
   Raise rear of vehicle and support on jack stands. Inspect entire exhaust system from turbocharger outlet to tailpipe for leaks, damage, or excessive corrosion. Check all exhaust hangers are intact and muffler is securely mounted. Verify exhaust exits behind passenger compartment and does not have excessive noise. Inspect fuel tank and lines for leaks or damage. Check rear differential and transfer case for fluid leaks.
8. 8

   Rear Suspension and Brake Inspection
   Inspect rear leaf springs for cracks, broken leaves, or sagging. Check rear shock absorbers for leaks and secure mounting. Verify U-bolts are tight and spring shackles move freely. Inspect rear brake components through wheel openings - check for fluid leaks at wheel cylinders or calipers depending on brake type. Look for excessively worn brake pads or shoes if visible.
9. 9

   Emissions and OBD System Check
   For 1996-2007 models, connect an OBD-II scanner to the diagnostic port located under the driver side dash. Turn ignition to ON position without starting engine - verify check engine light (MIL) illuminates then extinguishes after engine starts. Scan for diagnostic trouble codes - no emissions-related codes should be present. Note that diesel engines are often exempt from OBD-II readiness monitor requirements; verify state requirements. For 1994-1995 models without OBD-II, perform a visual inspection of emissions equipment.thout OBD-II, perform visual inspection of emissions equipment.
10. 10

    Interior Safety Equipment Check
    Verify driver and passenger seatbelts retract properly and latch securely. Test all seatbelt buckles for proper operation. Check that driver's seat adjusts and locks securely. Verify speedometer and other required gauges are operational. Test defroster for proper airflow to windshield. Check that all required warning lights illuminate during bulb check and extinguish appropriately.
11. 11

    Body and Frame Inspection
    Inspect door latches - all doors should open and close securely. Check for excessive body rust or damage, particularly in structural areas. Inspect frame rails and crossmembers for cracks, severe corrosion, or damage. Verify hood and tailgate/liftgate latch and release properly. Check that fuel filler cap seals properly.

Reassembly

1. Lower vehicle from jack stands and remove wheel chocks
2. Verify all inspection points have been documented
3. Complete required state inspection form with all findings
4. Affix inspection sticker if vehicle passes all required criteria

Verification

• Review all inspection criteria against state requirements to ensure nothing was missed
• Verify all documented deficiencies are accurate and clearly noted
• Confirm vehicle registration and VIN documentation is complete
• Ensure inspection sticker or rejection notice is properly completed per state regulations

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