Complete state safety inspection procedure for 2015-2020 Ford F-150 3.5L EcoBoost, verifying all required safety systems, lights, brakes, steering, suspension, and emissions components meet legal requirements.

Warnings

Tools required

Preparation

1. Park vehicle on level ground in well-lit inspection area
2. Ensure engine is cold or cooled down for safe inspection
3. Have vehicle registration and previous inspection records available
4. Verify VIN matches registration documents
5. Check that odometer reading is consistent and functional

Procedure

1. 1

   OBD-II System and Emissions Check
   Connect OBD-II scanner to diagnostic port located below driver side dash. Turn ignition to ON position without starting engine. Check for diagnostic trouble codes (DTCs). Verify check engine light (MIL) illuminates during bulb check and extinguishes after engine start. On 2015-2020 models, verify readiness monitors are set - at least 6 of 8 monitors must show ready status. Check for emissions equipment tampering including EGR system, catalytic converters, and evaporative emissions components.
2. 2

   Exterior Lighting System Verification
   Check operation of all exterior lights: headlights (low and high beam), front turn signals, front side markers, rear turn signals, brake lights, rear side markers, tail lights, reverse lights, and license plate light. Verify hazard lights function properly. Inspect lenses for cracks, discoloration, or damage that reduces light output. On F-150 models with LED lighting, check for individual LED failures within light assemblies.
3. 3

   Horn and Windshield System Check
   Test horn for proper operation and adequate volume. Inspect windshield for cracks or chips larger than 1 inch in driver's critical vision area or cracks extending to windshield edge. Test windshield wipers on all speeds including intermittent settings. Verify washer fluid sprays adequately on windshield. Check wiper blades for tears, separation, or excessive wear that leaves streaks.
4. 4

   Tire and Wheel Inspection
   Measure tread depth at multiple points on all four tires - minimum legal tread depth is typically 2/32 inch but verify state requirements. Inspect tires for uneven wear patterns, sidewall bulges, cuts, or exposed cords. Check tire size matches door jamb specification. Verify all tires are same size and type (no mixing radial/bias ply). Check tire pressure against door jamb specification (typically 35 psi front and rear for F-150). Inspect wheels for cracks, damage, or excessive corrosion. Verify all lug nuts are present and properly tightened.
5. 5

   Brake System Performance Test
   Start engine and depress brake pedal firmly - pedal should feel firm and not sink to floor. Check brake warning light extinguishes after engine start and parking brake release. Test parking brake holds vehicle on incline or resists movement. Listen for unusual brake noise during application. Check brake fluid level in master cylinder reservoir - should be between MIN and MAX marks. Inspect fluid color - dark or contaminated fluid indicates service needed but may not fail inspection.
6. 6

   Steering and Suspension Visual Inspection
   With vehicle on ground, check steering wheel for excessive play - turn wheel and verify less than 2 inches of free play before wheels respond. Start engine and verify electric power steering functions properly with no warning lights. Turn wheel lock to lock listening for grinding or binding. Check for steering wheel alignment when driving straight. Visually inspect steering shaft U-joints and coupling for wear or damage from driver position.
7. 7

   Raised Vehicle Undercarriage Inspection
   Safely raise vehicle on lift or jack stands supporting at frame points. Inspect exhaust system for leaks, excessive corrosion, or loose/missing hangers - pay special attention to manifold connections and catalytic converter welds. Check fuel tank and lines for leaks, damage, or improper routing. On RWD models, inspect driveshaft U-joints for play or torn boots. Check rear differential for leaks at pinion seal and cover.
   ⚠️Never work under vehicle supported only by hydraulic jack - always use proper jack stands
8. 8

   Suspension Component Inspection
   With vehicle raised, inspect front and rear shock absorbers for leaks or damage. Check control arm bushings for cracks, tears, or separation. Inspect ball joints for boots integrity and excessive wear - use pry bar to check for play if permitted by inspection protocol. Examine tie rod ends for torn boots or looseness. Check sway bar links and bushings for wear. Inspect leaf spring hangers, shackles, and u-bolts on rear suspension for cracks or looseness.
9. 9

   Brake Component Visual Inspection
   Remove at least two wheels (one front, one rear recommended) to inspect brake components. Check brake pad thickness - minimum typically 2mm but verify state requirement. Inspect rotors for excessive scoring, cracks, or warping. Check brake lines and hoses for leaks, cracks, bulging, or damage. Verify brake calipers mount securely and slide pins move freely. Inspect rear brake setup (disc brakes on most 2015-2020 F-150 models) for similar wear and damage. Reinstall wheels and torque lug nuts in star pattern.
10. 10

    Interior Safety Equipment Check
    Verify driver and passenger seat belts retract, extend, and latch properly. Check for fraying, cuts, or damaged webbing on all seat belts. Test seat belt warning light and chime function. Inspect driver seat for secure mounting - no excessive movement or broken tracks. Check rearview and side mirrors for proper adjustment range and secure mounting. Verify all required interior warning lights illuminate during bulb check and extinguish appropriately.
11. 11

    Final Road Test and Documentation
    Perform test drive to verify vehicle tracks straight, brakes operate evenly without pulling, transmission shifts smoothly through all gears, and no unusual noises or vibrations present. Verify speedometer functions accurately. Test 4WD engagement if equipped (note: base RWD models will not have this feature). Return to inspection area and lower vehicle if still raised. Complete all required inspection documentation noting odometer reading, any deficiencies found, and overall pass/fail determination.

Reassembly

1. Reinstall any wheels removed during brake inspection, torquing lug nuts to specification in star pattern
2. Disconnect OBD-II scanner and ensure diagnostic port cover is reinstalled if equipped
3. Return tire pressures to specification if adjusted during inspection
4. Clean any dirt or grease from inspection activities

Verification

• Confirm all inspection checklist items are documented per state requirements
• Verify no warning lights remain illuminated on instrument cluster
• Ensure all wheels are properly torqued and vehicle is safe to drive
• Review findings with vehicle owner and provide detailed explanation of any deficiencies requiring repair before passing inspection
• Affix inspection sticker per state regulations only if vehicle passes all requirements

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