Complete state safety inspection procedure for a 2015-2020 Ford F-150 with 5.0L V8 engine, covering all required inspection points including lights, brakes, suspension, steering, tires, and emissions systems.

Warnings

Tools required

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Ensure engine is cool enough to touch components safely
4. Have vehicle registration and previous inspection documents available
5. Verify fuel level is at least 1/4 tank for emissions testing readiness

Procedure

1. 1

   Perform OBD-II System Check
   Connect OBD-II scanner to diagnostic port located under driver side dashboard. Turn ignition to ON position without starting engine. Check for Diagnostic Trouble Codes (DTCs). Verify all emissions monitors are in READY status. Check that Malfunction Indicator Lamp (MIL/Check Engine Light) illuminates during bulb check and extinguishes after engine start. Document any stored codes or incomplete monitors.
2. 2

   Inspect Exterior Lighting Systems
   Check operation of headlights (low and high beam), turn signals (front and rear), parking lights, brake lights, reverse lights, and license plate light. Verify all lenses are intact without cracks or moisture. Check hazard flashers operate all four corners. Use brake pedal depressor if working alone. Replace any non-functioning bulbs before proceeding.
3. 3

   Check Horn and Windshield Components
   Test horn for proper operation. Inspect windshield for cracks or chips larger than allowable limits (typically no cracks in driver's viewing area). Test windshield wipers on all speeds and check wiper blade condition for tears or deterioration. Verify washer fluid sprays properly on windshield. Top off washer fluid if needed.
   ℹ️Windshield washer reservoir capacity is 3.5 quarts - located in engine bay on driver side
4. 4

   Inspect Tires and Wheels
   Check all four tires plus spare for tread depth using tread depth gauge - minimum legal depth is typically 2/32 inch. Inspect for uneven wear, bulges, cuts, or exposed cords. Verify tire pressures match door jamb specifications (typically 35 PSI front and rear for F-150). Check wheel lug nuts are present and not visibly damaged or loose. Inspect wheels for cracks or bends.
5. 5

   Raise Vehicle for Undercarriage Inspection
   Raise vehicle using floor jack at manufacturer-specified lift points (frame rails). Support vehicle with jack stands rated for vehicle weight under frame rails behind front wheels and ahead of rear axle. Ensure vehicle is stable before working underneath. Remove all four wheels for thorough brake and suspension inspection.
   ⚠️Never work under a vehicle supported only by a floor jack - always use rated jack stands
6. 6

   Inspect Brake System
   Check brake pad thickness at all four corners - minimum thickness typically 3mm or 1/8 inch. Inspect rotors for scoring, warping, or excessive rust. Check brake lines and hoses for leaks, cracks, or swelling. Verify calipers are not seized and slide pins move freely. Inspect parking brake cables for fraying or damage. Check brake fluid level in master cylinder reservoir - fluid should be between MIN and MAX marks.
7. 7

   Inspect Steering and Suspension Components
   Check ball joints for excessive play by prying between control arm and spindle. Inspect tie rod ends for looseness and torn boots. Check steering rack boots for tears or leaks. Inspect control arm bushings for deterioration or separation. Verify shock absorbers are not leaking and mounts are secure. Check sway bar links and bushings for wear. All components should have no excessive play or damage.
8. 8

   Check Exhaust System
   Inspect entire exhaust system from manifolds to tailpipe. Check for leaks, rust holes, or loose connections. Verify catalytic converters are present and heat shields are secure. Check exhaust hangers for damage. Listen for unusual rattles or leaks. Ensure tailpipe exits behind passenger compartment and is not blocked.
9. 9

   Inspect Fuel System and Frame
   Check fuel tank for damage, leaks, or excessive rust. Verify fuel filler cap seals properly. Inspect fuel lines for leaks or damage. Check frame rails and crossmembers for excessive rust, cracks, or damage that could affect structural integrity. Verify no aftermarket modifications violate safety regulations.
10. 10

    Check Rear Differential and Drive Components
    Inspect rear differential housing for leaks at pinion seal, axle seals, and cover gasket. Check driveshaft U-joints for play by rotating shaft and checking for movement. Verify driveshaft center support bearing (if equipped) is secure and not worn. Check CV boots on front axle if 4WD equipped.
11. 11

    Reinstall Wheels and Lower Vehicle
    Reinstall all four wheels ensuring hub surfaces are clean. Hand-tighten lug nuts in star pattern. Lower vehicle partially so tires contact ground but suspension not fully loaded. Torque all lug nuts to specification in star pattern using torque wrench. Fully lower vehicle and remove jack stands. Perform final torque check on all lug nuts.
12. 12

    Test Drive and Final Checks
    Perform brief test drive to verify brake operation, steering response, and unusual noises. Test parking brake holds vehicle on incline. Return to inspection area and check for fluid leaks. Verify all warning lights extinguish after engine start except applicable indicators (low fuel, etc.). Verify mirrors are present and adjustable. Check seat belts retract and latch properly in all positions.

Reassembly

1. Ensure all wheels are torqued to specification after test drive
2. Disconnect OBD-II scanner and ensure diagnostic port cover is in place
3. Verify no tools or equipment left in engine bay or under vehicle

Verification

• All exterior lights function properly and lenses are intact
• No active DTCs present and MIL lamp operates correctly
• Tire tread depth meets minimum requirements and pressures are correct
• Brake components meet minimum thickness and show no leaks
• Steering and suspension components have no excessive play or damage
• Exhaust system is leak-free with catalytic converters present
• No fluid leaks observed from engine, transmission, or differential
• All safety equipment (horn, wipers, seat belts, mirrors) functions properly
• Vehicle passes all state-specific inspection requirements

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