Perform a comprehensive state safety inspection of a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, checking all required safety systems, lights, brakes, tires, suspension, and emissions components per state requirements.

Warnings

Tools required

Preparation

1. Review state-specific inspection requirements and prepare inspection form
2. Verify vehicle has completed sufficient drive cycles for emissions readiness monitors (typically 50-100 miles since last code clear)
3. Position vehicle on level ground with parking brake released
4. Start engine and allow to reach normal operating temperature
5. Check that registration documents match VIN on vehicle

Procedure

1. 1

   Perform OBD-II emissions system check
   Connect OBD-II scanner to diagnostic port located under driver side dash. Turn ignition to ON position without starting engine. Check for diagnostic trouble codes (DTCs) in all modules. Verify readiness monitors show READY status for Catalyst, Oxygen Sensor, EVAP System, and EGR System. Note that up to 2 non-continuous monitors may show NOT READY in some states. Record any pending or confirmed codes. Check that MIL (Check Engine Light) illuminates with key ON and extinguishes when engine starts.
2. 2

   Inspect exterior lighting and turn signals
   Check operation of headlights (low and high beam), parking lights, tail lights, brake lights, turn signals (front and rear), hazard lights, and reverse lights. Verify license plate light operates. Check for proper headlight aim - low beams should not project higher than headlight centerline at 25 feet. Inspect all lenses for cracks or damage. Verify amber turn signal lenses front, red rear.
3. 3

   Check horn, windshield wipers, and washer system
   Test horn for proper operation. Check all wiper speeds (intermittent, low, high) for proper blade contact and no streaking that obstructs driver view. Operate windshield washer and verify fluid sprays onto windshield. Inspect wiper blades for tears, hardening, or missing sections. Check windshield for cracks or damage in driver's primary viewing area.
4. 4

   Inspect tires and wheels
   Measure tread depth at multiple points on all four tires using depth gauge - minimum legal tread depth is typically 2/32 inch (1.6mm). Check for uneven wear patterns indicating alignment or suspension issues. Inspect sidewalls for cuts, bulges, or weather cracking. Verify all tires are same size and type (no mixing radial/bias ply). Check that all wheel lug nuts are present and properly tightened. Inspect wheels for damage or cracks. Verify tire pressures match door placard specification (typically 35 PSI front and rear for F-150).
5. 5

   Test brake system operation
   With engine running, depress brake pedal firmly and hold - pedal should feel firm and not sink slowly to floor. Test parking brake by engaging on slight incline - vehicle should hold position. Release parking brake and verify indicator light extinguishes. Road test vehicle and verify smooth brake application without pulling to either side, pulsation, or unusual noises. Check brake pedal reserve - should have at least 1 inch clearance from floor when fully depressed.
6. 6

   Raise vehicle and inspect brake components
   Safely raise vehicle on lift or support securely on jack stands. Remove all four wheels. Inspect brake pads/shoes for minimum thickness - front pads minimum 3mm, rear pads minimum 2mm. Check brake rotors/drums for scoring, cracking, or excessive wear. Inspect brake lines and hoses for leaks, damage, cracking, or bulging. Verify caliper slide pins move freely. Check for brake fluid leaks at calipers, wheel cylinders, and connections. Inspect parking brake cables for fraying or binding.
7. 7

   Inspect suspension and steering components
   With vehicle raised, grasp each tire at 12 and 6 o'clock positions and attempt to rock vertically - excessive play indicates worn ball joints or wheel bearings. Grasp at 3 and 9 o'clock and rock horizontally - play indicates tie rod or wheel bearing wear. Inspect all ball joint boots for tears or grease leakage. Check upper and lower control arm bushings for deterioration or separation. Inspect tie rod ends for looseness or damaged boots. Check sway bar links and bushings for wear. Verify shock absorbers show no leakage and are securely mounted. On 4WD models, inspect CV axle boots for tears and check for axle play.
8. 8

   Check exhaust system and catalytic converters
   Inspect entire exhaust system from manifolds to tailpipe for leaks, damage, or excessive corrosion. Check that all hangers are intact and exhaust components do not contact frame or body. Verify catalytic converters are present and original equipment (EcoBoost has four catalytic converters - two per bank). Look for evidence of tampering or aftermarket components. Check heat shields for secure mounting. Start engine and listen for exhaust leaks. Verify exhaust exits behind passenger compartment.
9. 9

   Inspect fuel system for leaks
   Visually inspect fuel tank for damage or leaks. Check fuel filler neck and cap for proper seal. Inspect visible fuel lines for damage, deterioration, or leakage. Verify fuel cap seals properly and has intact gasket. Check for fuel odor in engine compartment or underneath vehicle. Inspect EVAP canister and lines for damage.
10. 10

    Check fluid levels and leaks
    With engine at operating temperature on level ground, check engine oil level on dipstick - should be between MIN and MAX marks. Check coolant level in overflow reservoir - should be at FULL COLD mark when cold. Verify power steering fluid level (if equipped - some models use electric power steering). Check brake fluid level in master cylinder reservoir - should be between MIN and MAX. Inspect under vehicle for any fluid leaks from engine, transmission, transfer case, or differentials. On 4WD models, verify front and rear differential and transfer case show no external leakage.
11. 11

    Test seat belts and restraint systems
    Check all seat belts for proper operation - should retract smoothly and latch securely. Inspect webbing for cuts, fraying, or burns. Test emergency locking mechanism by pulling sharply - belt should lock. Verify airbag warning light illuminates briefly with ignition ON then extinguishes. Check that all seat belt buckles and mounting points are secure. Confirm child seat tether anchors are accessible and undamaged.
12. 12

    Inspect body and frame for damage
    Check body for excessive rust or corrosion that compromises structural integrity. Inspect frame rails and cross members for damage, cracks, or improper repairs. Verify no sharp edges or protruding objects that could cause injury. Check that all doors, hood, and tailgate open and close properly and latch securely. Inspect door hinges and latches for wear. Verify no missing or non-functional safety equipment.
13. 13

    Reinstall wheels and perform final checks
    Reinstall all four wheels, torquing lug nuts to specification in a star pattern. Lower vehicle to ground. Verify parking brake holds vehicle on incline. Check that all dashboard warning lights function properly and no warning lights remain illuminated with engine running (except any pre-existing conditions noted). Test drive vehicle to verify steering, braking, and overall operation. Complete inspection form with all findings.

Reassembly

1. Ensure all wheels are properly torqued in star pattern to 140 Nm (103 lb-ft)
2. Verify all fluid levels are correct and caps are properly installed
3. Clear any test equipment and ensure no tools remain in engine bay

Verification

• Confirm no diagnostic trouble codes present and readiness monitors show READY status
• Verify all lights, wipers, horn, and safety equipment operate correctly
• Confirm brake pedal feels firm with at least 1 inch reserve from floor
• Verify no fluid leaks observed during or after inspection
• Check that all wheels are properly torqued and tire pressures are correct
• Complete state inspection form documenting all pass/fail items
• Affix inspection sticker if vehicle passes all requirements

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