State Inspection

Perform a state vehicle safety inspection on a 2007 Ram 3500 with 5.9L Cummins diesel engine, checking all safety-critical systems and components required by state regulations.

Warnings

Tools required

Preparation

1. Park vehicle on level ground in well-lit inspection area
2. Apply parking brake and place wheel chocks behind rear wheels
3. Ensure engine is cold or warm, not hot from recent operation
4. Have vehicle registration and previous inspection documents available
5. Verify VIN matches registration documents

Procedure

1. 1

   Scan for diagnostic trouble codes
   Connect OBD-II scanner to diagnostic port located under driver side dashboard. Turn ignition to ON position without starting engine. Scan for any stored or pending diagnostic trouble codes (DTCs). Record any codes found. Check that check engine light (MIL) illuminates during bulb check and extinguishes after engine start. Vehicle will fail inspection if MIL is illuminated or if emissions-related codes are present.
2. 2

   Inspect all exterior lighting
   Check operation of headlights (low and high beam), parking lights, turn signals (front and rear), hazard lights, brake lights (all three including center high-mount), reverse lights, and license plate light. Verify all lenses are intact without cracks. Check headlight aim - both headlights should illuminate road evenly without excessive upward aim that would blind oncoming traffic.
3. 3

   Check horn, wipers, and washers
   Test horn for proper operation. Operate windshield wipers on all speeds and verify blades make clean contact without streaking or missing sections. Test windshield washer system for proper spray pattern covering both sides of windshield. Check wiper blade condition - replace if torn, cracked, or leaving streaks.
4. 4

   Inspect glass and mirrors
   Examine windshield for cracks, chips, or damage in driver's field of vision. Check that all required mirrors (driver side, passenger side, and interior rearview) are present, secure, and provide adequate visibility. Inspect all other glass (side windows, rear window) for major damage. Minor chips outside driver's direct view are typically acceptable.
5. 5

   Check tires and wheels
   Inspect all four tires for tread depth using tread depth gauge - minimum legal depth is typically 2/32 inch but verify state requirements. Check for uneven wear, bulges, cuts, or exposed cords. Verify tire size matches all four corners and is appropriate for vehicle. Check tire pressure against door jamb specification (typically 60-80 PSI front, 70-80 PSI rear for 3500 single rear wheel). Inspect wheels for cracks or damage. Verify all lug nuts are present and tight.
6. 6

   Test service brake system
   Start engine and allow air pressure to build if equipped with exhaust brake. Press brake pedal firmly and verify pedal feels solid without sinking to floor. Pedal should not require excessive force. With engine running, depress brake pedal and hold - pedal should not slowly sink indicating master cylinder leak. Check brake fluid level in reservoir - should be between MIN and MAX marks. Have assistant depress brake pedal while you verify all brake lights illuminate.
   ⚠Low or spongy brake pedal indicates brake system failure requiring immediate repair before continuing inspection
7. 7

   Test parking brake
   With vehicle on level ground and transmission in neutral, apply parking brake fully. Attempt to move vehicle by releasing service brake - vehicle should remain stationary. Parking brake should hold vehicle securely without rolling. Release parking brake and verify release indicator light extinguishes on instrument cluster.
8. 8

   Inspect steering system
   With engine running (for power steering), turn steering wheel lock to lock. Check for excessive play in steering wheel - more than 2 inches of free play typically fails inspection. Listen for unusual noises indicating worn components. Verify steering returns to center naturally. Check power steering fluid level in reservoir - should be at FULL COLD mark with cold engine. Inspect reservoir cap and hoses for leaks.
9. 9

   Check seat belts and safety restraints
   Inspect all seat belts for proper operation. Pull each belt out fully and verify it retracts smoothly. Check webbing for fraying, cuts, or burns. Verify buckles latch and release properly. Confirm all required seat belt mounting points are secure and not damaged. Test that seat belt pretensioners (if equipped) show no signs of deployment.
10. 10

    Raise vehicle for undercarriage inspection
    Raise vehicle using floor jack at manufacturer-specified jacking points. Support securely on jack stands rated for vehicle weight (3500 series requires heavy-duty stands). Never work under vehicle supported only by jack. Ensure vehicle is stable before proceeding with undercarriage inspection.
    ⚠️Vehicle must be supported on jack stands, never on floor jack alone. Ram 3500 is extremely heavy - ensure jack stands are rated for at least 4 tons per stand
11. 11

    Inspect exhaust system
    Examine entire exhaust system from turbocharger outlet to tailpipe. Check for holes, cracks, or severe corrosion that could allow exhaust gases to enter passenger compartment. Verify all hangers are intact and exhaust components are not contacting frame, body, or fuel tank. Inspect exhaust manifold and downpipe for cracks or leaks. The 2007 5.9L Cummins was not equipped with a diesel particulate filter (DPF) from the factory, so no DPF inspection is required; verify the exhaust system matches the original non-DPF configuration.
    ⚠Exhaust system may be hot even after engine has been off for some time. Allow adequate cooling before inspection
12. 12

    Inspect suspension and steering components
    Examine front suspension including control arms, ball joints, tie rod ends, and steering linkage for excessive wear or damage. Check that all rubber bushings are intact and not severely cracked. Inspect for fluid leaks from steering gear or power steering hoses. Check shock absorbers for leaks or damage. Inspect leaf spring bushings, U-bolts, and shackles on rear suspension. All components should be tight with no excessive movement.
13. 13

    Check brake components
    Inspect brake lines, hoses, and fittings for leaks, cracks, or damage. Verify brake hoses are not rubbing on tires or suspension components. Examine brake calipers for leaks and verify they are securely mounted. Check brake pad or shoe thickness through wheel spokes or by removing wheels if necessary - minimum thickness varies by state but typically 3mm or greater. Inspect brake rotors or drums for excessive wear, scoring, or cracks.
14. 14

    Inspect driveline and transfer case
    Check driveshafts for damaged or missing balance weights. Inspect U-joints for excessive play by attempting to rotate driveshaft with hand - should have minimal movement. Inspect the front axle U-joints and axle shaft seals for excessive play, leaks, or damage. Inspect transfer case, front differential, and rear differential for fluid leaks at seals and gaskets. Check 4WD engagement mechanism linkage is intact and secure.
15. 15

    Inspect fuel system and fluid leaks
    Examine fuel tank, fuel lines, and connections for leaks or damage. Verify fuel tank is securely mounted with all straps intact. Check for fuel odor indicating leaks. Inspect engine oil pan, transmission, and transfer case for active fluid leaks - minor seepage is typically acceptable but active drips that form drops may fail inspection. Check coolant hoses and radiator for leaks. Lower vehicle from jack stands when inspection is complete.

Reassembly

1. Lower vehicle safely from jack stands to ground
2. Remove wheel chocks
3. Ensure all inspection items are documented on inspection form
4. Clean any grease or dirt from steering wheel and controls from inspection process

Verification

• Review inspection checklist and verify all items meet state requirements
• Confirm no dashboard warning lights are illuminated with engine running
• Verify all safety systems tested during inspection are functioning properly
• Test drive vehicle to confirm brakes, steering, and handling are normal
• If vehicle passes all inspection points, complete required state inspection documentation and affix inspection sticker
• If vehicle fails any inspection point, provide detailed written documentation of failure items to vehicle owner

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