CVSA Roadcheck 2025 Results: A Guide for Your Fleet

The results from CVSA International Roadcheck 2025 are out, and they serve as a massive report card for the entire trucking industry. Think of this annual 72-hour inspection blitz as more than just a date on the calendar. It’s a critical benchmark that shows exactly how your fleet’s safety program stacks up against tens of thousands of others across North America.

Getting a handle on these high-level numbers is the first step to dialing in your own compliance strategy and staying ahead of the curve.

A High-Level Look at the 2025 Inspection Results

When the CVSA drops its findings, it’s like getting a peek at the industry’s final exam scores. You can see which subjects everyone aced and, more importantly, where the most common failures happened. This data is gold for spotting potential weak spots in your own operation before an officer finds them for you during a roadside inspection.

The numbers from this year’s event tell a pretty clear story. According to the Commercial Vehicle Safety Alliance, inspectors knocked out a staggering 56,178 inspections across the U.S., Canada, and Mexico between May 13-15.

The final tally? An overall vehicle out-of-service (OOS) rate of 18.1% and a driver OOS rate of 5.9%. That translates to 10,148 trucks and 3,342 drivers getting parked on the spot for critical violations. You can see the full breakdown in the official CVSA announcement.

Key Takeaways for Your Fleet

These top-line stats give a solid overview of where things stand. Here are the immediate points you should be thinking about:

• Vehicle Condition is Everything: Almost one out of every five trucks inspected was put out of service. This is a huge reminder of how important solid pre-trip inspections and a robust preventive maintenance program really are.
• Driver Compliance Still Matters: The driver OOS rate is lower, sure, but it still represents thousands of delayed loads and major compliance headaches. Inspectors are still zoning in on issues with logs and driver credentials.
• Most Fleets Are Passing: On the bright side, 81.6% of vehicles and 94.1% of drivers got through the blitz with no OOS violations. This is proof that acing an inspection is totally possible with the right prep and a strong safety culture.

The goal for your fleet is to be in that majority that sails right through an inspection. Earning a CVSA decal is the tangible reward for that hard work, signaling to officers that your truck recently passed a tough, comprehensive Level 1 inspection check.

The data is obvious: mechanical fitness continues to be a much bigger hurdle for the industry than driver-related issues. For any fleet looking to step up its game, understanding the specifics of what a CVSA sticker signifies and how to earn one is a perfect starting point.

Now, let’s dig into the nitty-gritty of the specific violations that took so many trucks off the road.

Why Brakes and Tires Topped the Vehicle Violations List

An out-of-service order is more than just a sticker on a window; it’s a grinding halt to your revenue and schedule. The CVSA Roadcheck 2025 results once again put a spotlight on the usual suspects pulling trucks off the road: brake systems and tires.

Understanding why these components consistently top the violations list is the key to breaking the cycle.

It’s rarely one catastrophic failure that grounds a truck. Most violations are a story of small, overlooked issues that snowball into a major problem. A tiny air leak, a slightly worn tread, or a brake just out of adjustment might seem minor during a rushed pre-trip, but to a trained inspector, they are red flags signaling a lack of systematic maintenance.

These recurring equipment failures underscore a critical truth for your fleet: proactive maintenance isn’t a cost center, it’s a profit protector.

The Anatomy of a Brake Violation

Brake-related issues were the number one reason vehicles were placed out of service during Roadcheck 2025, accounting for a massive chunk of all OOS violations. Think of a truck’s air brake system like the human circulatory system—it’s complex, with many parts that must work together perfectly. A single clog or leak can compromise the entire system’s integrity.

Inspectors aren’t just looking for total brake failure. They’re trained to spot the early warning signs you might miss.

Here are the specific failures that inspectors commonly flagged:

• Brakes Out of Adjustment: This is a persistent issue. When the pushrod stroke exceeds the legal limit on even one brake, it reduces the braking force on that wheel, forcing other brakes to work harder and potentially overheat.
• Air System Leaks: A slow, hissing leak might not seem urgent, but it can drain your air pressure, leading to brake failure in an emergency. Inspectors are meticulous about checking for these audible and inaudible leaks.
• Worn Components: Inspectors found cracked brake drums, worn-out brake linings, and damaged air hoses. These are issues that a thorough pre-trip or regular PM schedule should catch long before a roadside inspection.

An out-of-service brake violation is rarely a surprise. It’s typically the result of deferred maintenance or incomplete inspections finally catching up with a vehicle. Every component, from the air compressor to the slack adjusters, plays a vital role.

A deep understanding of how each part functions is essential for effective prevention. If you’re looking to reinforce your team’s knowledge, reviewing our complete guide on preventing air brake system leaks can be a valuable training tool. You can also check out our short video below: 

Why Tires Continue to Be a Trouble Spot

Right behind brakes, tire violations were a major cause for concern during the CVSA Roadcheck 2025. Your tires are the only part of the truck that actually touches the road, yet their condition is often taken for granted until it’s too late.

A tire failure isn’t just a compliance issue; it’s a severe safety risk. Inspectors focus heavily on tires because a blowout can have catastrophic consequences.

These were the top tire violations inspectors were writing up:

• Insufficient Tread Depth: The FMCSA has clear minimums (4/32-inch for steer tires, 2/32-inch for all others). Anything less is an automatic violation.
• Visible Damage: This includes cuts, cracks, bulges, or any exposed belts or fabric. These are signs of internal damage and an impending blowout.
• Underinflation: Improperly inflated tires run hot, wear unevenly, and can fail suddenly. Inspectors check tire pressure and look for the visual cues of a low tire.

Think of your tire management program as a health and wellness plan for your fleet’s feet. Regular check-ups (pressure gauges), a balanced diet (proper inflation), and preventive care (rotations and alignments) are non-negotiable for keeping your trucks on the road and out of the inspection bay. A simple walk-around can reveal most of these issues before they become costly OOS events. Check out our article on preventing tire violations for more information.

The Driver Violations You Need to Prevent Now

A mechanically sound truck is only half the battle. Driver compliance is the other, equally critical part of the safety equation that determined a pass or fail during CVSA Roadcheck 2025. Even the most perfectly maintained rig can get slapped with an out-of-service order if the person behind the wheel has their paperwork out of line.

This year’s inspection blitz proved it again: while vehicle violations are more common, driver-related issues still put thousands of trucks on the sidelines. These problems usually boil down to simple, preventable mistakes with logs and documents. Making these topics a priority in your safety meetings is one of the fastest ways to boost your fleet’s performance.

The Ever-Present Challenge of Hours of Service

Once again, Hours of Service (HOS) violations were a top reason for putting drivers out of service. This isn’t always about your team intentionally pushing their limits; more often, it’s about the small details that get overlooked in the logbook.

Think of an ELD log like a bank statement—every single entry has to be spot-on, or the whole thing looks suspicious.

Inspectors are sharpshooters when it comes to spotting inconsistencies that hint a log doesn’t match what actually happened. A “form and manner” violation might not sound like a big deal, but to an officer, it’s a bright red flag that can trigger a much deeper, more painful audit of your entire operation.

Common HOS blunders include:

• Incorrect Log Entries: This can be as simple as forgetting to log a pre-trip inspection or not properly adding a note for a duty status change.
• Exceeding Driving Limits: Going over the 11-hour driving or 14-hour on-duty window, even by a few minutes, is a black-and-white violation.
• False Logs: This is the big one. Inspectors are pros at finding discrepancies, like GPS data showing a truck moving while the driver is logged “off-duty.”

The best defense against HOS violations is a deep, real-world understanding of the rules. It’s not just about knowing the time limits. It’s about mastering the finer points of logging, personal conveyance, and handling edits the right way.

Consistent training and regular log audits are your best friends here. For a much deeper look, our guide on preventing Hours of Service violations gives you practical strategies you can use immediately.

Credentials and Qualifications Under Scrutiny

After Hours of Service, an inspector’s first checks are almost always on the driver’s basic qualifications. These are the foundational documents proving a driver is legally allowed to be on the road. A simple mistake here can mean an instant out-of-service order.

It’s like trying to get on a plane with an expired passport. It doesn’t matter how packed or prepared you are for your trip—you aren’t going anywhere. It’s the exact same for your drivers. During Roadcheck 2025, inspectors were laser-focused on licenses and medical cards.

These are the key areas to audit with every single one of your drivers:

1. Valid CDL and Proper Endorsements: Is the license current? Do they have the right class and any needed endorsements (like hazmat or tanker) for the load they’re pulling?
2. Current Medical Examiner’s Certificate: An expired “med card” is a non-negotiable ticket to the penalty box. You absolutely need a system to track these expiration dates for your entire fleet.
3. Proof of Annual Inquiry and Certification: Are you running annual MVRs on all your drivers and keeping those records in their Driver Qualification files like you’re supposed to?

These violations are 100% preventable with a solid system. Regular reminders and a simple process for your team to turn in updated documents can wipe out these expensive and embarrassing roadside headaches. A strong DQ file management system isn’t just for passing audits; it’s for staying compliant every single day.

How This Year’s Results Compare to the Past

Looking at the CVSA Roadcheck 2025 results in a vacuum only tells you part of the story. To really get a handle on what these numbers mean for your fleet, you have to put them in context. Are we actually getting better as an industry, or are the same old problems just showing up with a new date stamped on them?

When you place this year’s data next to historical results, you start to spot the important trends. Suddenly, the annual inspection blitz isn’t just a news headline; it becomes a strategic tool. You can see where enforcement is likely headed and which compliance areas need your attention most.

Unpacking the Year-Over-Year Trends

At first glance, the out-of-service rates might look like they’re just bouncing around from year to year. But if you dig a little deeper, you’ll see a consistent laser focus on core safety principles. The industry’s performance tends to hover within a pretty specific range, which tells us that the fundamental challenges in maintenance and driver compliance aren’t going away.

Let’s look at the numbers. The CVSA Roadcheck 2025 data showed an 18.1% vehicle out-of-service rate and a 5.9% driver out-of-service rate. How does that stack up? Back in 2019, we saw a 17.9% vehicle OOS rate and a 4.2% driver OOS rate. Then 2020’s vehicle OOS rate jumped to a notable 20.9%. This data paints a clear picture of a continuous push to get unsafe trucks and drivers off the road.

You can dive into a full history of these large-scale enforcement events and their outcomes in CVSA’s official results archive. This historical view is critical because it proves that while the exact percentages shift, the main problem areas—especially brakes, tires, and Hours of Service—are always on the inspectors’ radar.

What Has Changed and What Has Stayed the Same

Comparing the results from past blitzes helps you see both the stubborn, recurring problems and any new issues that are popping up. It helps you answer a key question: is your fleet struggling with the same things as everyone else?

Here’s what the historical data is telling us loud and clear:

• Brakes Are Still King: Year in and year out, brake problems are the number one reason trucks get put out of service. This isn’t a fluke; it’s a sign that the industry as a whole is still finding it tough to keep up with brake maintenance.
• Driver Violations Are a Sticky Problem: The driver OOS rate is much lower than the vehicle rate, but it’s been creeping upward lately. That suggests keeping logbooks accurate and driver qualifications in order is becoming a bigger headache for many carriers. Going forward, we expect that there will continued to be an increased focus on English Language Proficiency (ELP) for all CMV drivers. 
• Inspection Volume Holds Steady: The number of inspections during Roadcheck is always high, usually landing somewhere between 50,000 and 67,000. This shows a solid, ongoing commitment to this kind of high-visibility enforcement.

The real takeaway from comparing past results is that the fundamentals never go out of style. A strong preventive maintenance program and rigorous driver training were key to success five years ago, and they remain just as vital today.

Your Action Plan for Acing the Next Roadcheck

The results from CVSA Roadcheck 2025 are more than just numbers—they’re a playbook. The best way to handle the next inspection blitz isn’t scrambling at the last minute; it’s getting your game plan in order today. By turning this year’s findings into a solid action plan, you can build a culture of safety that makes Roadcheck feel like just another day on the road, not a three-day crisis.

This isn’t just about fixing what’s broken. It’s about creating a system so solid that violations rarely happen in the first place.

Conduct Mock Inspections with Purpose

The best way to prepare for a test is to take a practice one. Conducting your own mock inspections is a powerful tool, but they have to mirror what officers actually look for. Don’t just go through the motions; use the CVSA Roadcheck 2025 results as your guide.

Start by creating an inspection checklist that hammers the top violation categories from this year:

• Brake Systems: Don’t just listen for air leaks. Get out the tape measure and check pushrod travel on every single brake. This is a top-tier Out-of-Service violation that’s easy for an inspector to spot and completely preventable on your end.
• Tires: Go beyond a simple thump and pressure check. Train your team to hunt for cuts, bulges, and exposed belts. Hammer home the 4/32-inch tread depth requirement for steer tires and 2/32-inch for all others.
• Driver Documentation: Audit your drivers’ cabs. Are their CDL, medical card, and ELD immediately accessible? Is their DOT fire extinguisher secured properly and easily accessible? A messy, disorganized cab makes an inspector suspicious before they even start looking at the truck.

Think of these mock inspections as an open-book test. The CVSA has already given you the answer key by publishing the top violations. Your job is to use that intel to find and fix your weak spots before they do.

Reinforce Training with the “Why”

Simply telling your team to “do a better pre-trip” is a recipe for failure. Real, effective training connects the dots between the rules and real-world consequences. You have to explain the “why” behind the regulation, and the CVSA Roadcheck 2025 results give you the perfect, data-backed material for your next safety meeting.

Instead of just listing violations, frame the conversation around preventing disaster:

• For Brakes: Explain how one out-of-adjustment brake forces the others to work harder, dramatically increasing stopping distance and the risk of overheating on a long grade.
• For Hours of Service: Show them how simple “form and manner” violations in their RODS can eventually trigger a full-blown DOT audit that puts everyone under a microscope.
• For Cargo Securement: Discuss how a loose strap isn’t just a fine—it’s a massive public safety risk that can lead to catastrophic accidents on the highway. Check out our guide to the FMCSA load securement regulations for more help with this.

When your team understands the potential impact of a small oversight, they become active partners in compliance, not just employees following a checklist.

Fine-Tune Your Maintenance Schedules

Your preventive maintenance (PM) program should be a living document, not a static, set-it-and-forget-it schedule. Use the nationwide data from CVSA Roadcheck 2025 to sharpen your approach. If brake systems accounted for a massive percentage of OOS violations across the country, it’s a clear signal to double down on your own brake maintenance.

This means going deeper than the standard PM checklist. You might decide to:

1. Increase Inspection Frequency: Instead of checking slack adjusters every 90 days, maybe you move to a 60-day interval, especially for trucks running in tough conditions.
2. Focus on Component Lifecycles: Start tracking the age and mileage of critical parts like air hoses, brake chambers, and S-cams. Replace them based on proactive schedules, not just when they fail.
3. Invest in Better Tooling: Make sure your shop has the right tools for the job, like quality pressure gauges and proper tools to measure brake stroke accurately. Guesswork doesn’t cut it.

By using the industry’s report card to grade your own PM program, you shift from a reactive repair model to a proactive one that keeps your trucks rolling clean. A great place to start is our detailed guide on preparing for CVSA Roadcheck, which offers even more actionable steps.

Frequently Asked Questions about CVSA Roadcheck

Navigating DOT compliance can feel like a full-time job, pulling you away from what you do best—running your business. My Safety Manager takes that burden off your shoulders. For a simple flat fee, we handle everything from driver qualification to CSA score management, ensuring you’re always prepared for events like Roadcheck. Let us build your culture of safety so you can focus on growth. Learn how My Safety Manager can protect your fleet.