Perform a state safety inspection on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine, checking all required safety systems, lights, brakes, tires, emissions, and fluid levels per state requirements.

Warnings

Tools required

Preparation

1. Park vehicle on level ground in well-lit inspection area
2. Set parking brake and place transmission in Park
3. Allow engine to cool if previously running
4. Gather inspection checklist and forms specific to your state requirements
5. Ensure vehicle VIN is accessible and matches registration documents

Procedure

1. 1

   Perform OBD-II emissions check
   Connect OBD-II scanner to diagnostic port located below driver side dashboard. Turn ignition to ON position without starting engine. Check for diagnostic trouble codes (DTCs) and verify all emissions monitors are in 'Ready' status. For 2021-2024 F-150, most states allow 1-2 monitors to be 'Not Ready' on newer vehicles, but check local requirements. Record any DTCs found.
2. 2

   Inspect all exterior lighting
   Check operation of headlights (low and high beam), turn signals (front and rear), brake lights, reverse lights, license plate light, and hazard flashers. Verify all lenses are intact without cracks. Check headlight aim if required by state. For the F-150, verify LED daytime running lights function properly if equipped.
3. 3

   Check horn and windshield wipers
   Test horn for proper operation. Activate windshield wipers on all speeds and verify they clear windshield properly without streaking. Check washer fluid spray pattern and ensure both nozzles function. Inspect wiper blades for tears, cracks, or separation from frame.
4. 4

   Inspect windshield and glass
   Examine windshield for cracks, chips, or damage in driver's field of vision. Most states fail inspections for cracks longer than specified length (typically 6 inches) or multiple chips in critical viewing area. Check all other windows and mirrors for compliance. Verify VIN plate visibility through windshield.
5. 5

   Check tire condition and pressure
   Measure tread depth on all four tires using tread depth gauge. Minimum legal tread depth is typically 2/32 inch, but verify state requirement. Inspect tires for uneven wear, bulges, cuts, or exposed cords. Check tire pressure against door jamb placard specification (typically 35 PSI front and rear for F-150). Verify all tires are same size and properly rated for vehicle.
6. 6

   Raise vehicle and secure on jack stands
   Raise front of vehicle using floor jack at designated front jacking point on frame. Place jack stands under frame rails near front suspension. Lower vehicle onto stands. Repeat process for rear, using rear axle or frame jacking points. Ensure vehicle is stable before proceeding with undercarriage inspection.
   ⚠️Never crawl under vehicle supported only by hydraulic jack. Jack failure can cause death or severe injury.
7. 7

   Inspect steering and suspension components
   Check steering linkage, tie rod ends, and ball joints for excessive play or worn boots. Inspect shock absorbers for leaks. Examine control arm bushings for deterioration. On F-150 RWD, check front upper and lower control arms and steering gear mounting. Look for bent or damaged components. Any excessive play in steering components is typically an inspection failure.
8. 8

   Inspect brake system
   Examine brake lines and hoses for leaks, cracks, or damage. Check brake pad thickness through wheel openings (minimum typically 2-3mm depending on state). Inspect rotors for scoring or excessive wear. Examine rear brake components. Check for any fluid leaks at calipers or wheel cylinders. Verify parking brake holds vehicle on incline if testable.
9. 9

   Check exhaust system
   Inspect entire exhaust system from manifolds to tailpipe for leaks, holes, or loose connections. Check catalytic converters are present and appear intact (no hollowing or damage). Verify exhaust hangers are secure. Listen for any exhaust leaks that would allow gases to enter passenger compartment. On 3.5L EcoBoost, verify both turbocharger exhaust outlets are leak-free.
10. 10

    Inspect driveline and undercarriage
    Check driveshaft for damage or excessive play in U-joints. Inspect rear differential for leaks. Examine frame and crossmembers for rust, cracks, or structural damage. Check fuel tank and fuel lines for leaks or damage. Verify heat shields are present and secure.
11. 11

    Lower vehicle and perform brake test
    Carefully raise vehicle off jack stands and remove stands. Lower vehicle completely to ground. If required by state, perform brake pedal force test or rolling brake test. Otherwise, test drive vehicle briefly to verify brakes apply evenly without pulling. Parking brake should hold vehicle on grade.
12. 12

    Check fluid levels and leaks
    With engine cool, check engine oil level on dipstick. Verify brake fluid level in master cylinder reservoir (should be between MIN and MAX). Check coolant level in overflow reservoir. Inspect power steering system (F-150 uses electric power steering, no fluid required). Look for any fluid leaks under vehicle or in engine bay. Low fluid levels or active leaks may cause inspection failure.
13. 13

    Inspect seat belts and interior safety items
    Test all seat belts for proper retraction and latching. Check for fraying or cuts in webbing. Verify airbag warning light illuminates briefly at key-on then extinguishes (staying on indicates fault). Test all doors open and close properly with functioning latches. Verify rearview and side mirrors are present and securely mounted.
14. 14

    Complete final checks and documentation
    Start engine and verify no unusual noises or warning lights remain illuminated on dashboard. Confirm check engine light is not on. Review all inspection points against state checklist. Complete inspection documentation, noting any deficiencies found. Apply inspection sticker if vehicle passes all requirements, or provide rejection notice with required repairs if vehicle fails.

Reassembly

1. No disassembly required for standard state inspection
2. If wheels were removed for brake inspection, torque lug nuts to 140 Nm (103 lb-ft) in star pattern

Verification

• Verify all required inspection checklist items are documented
• Confirm no warning lights are illuminated on instrument cluster
• Ensure all tested components returned to proper operating condition
• Verify inspection sticker or documentation is properly completed
• Test drive vehicle briefly to confirm all systems operate normally after inspection

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