Ford Super Duty Fleet Inspection Checklist

Comprehensive inspection procedures for Ford F-250, F-350, F-450, and F-550 Super Duty fleet vehicles.

Super Duty Fleet Inspection Overview

Regular fleet inspections are essential for maintaining safety, compliance, and reliability of Ford Super Duty trucks. This checklist is designed for fleet managers and technicians managing F-250, F-350, F-450, and F-550 vehicles across various applications. Consistent inspection practices help identify issues early, reduce downtime, and extend vehicle life while ensuring DOT compliance for commercial fleets.

Critical Inspection Procedures

Follow these structured procedures for thorough inspection of Super Duty fleet vehicles.

Diesel Engine Inspection

  • Check oil level and condition (Power Stroke specific)
  • Inspect for oil leaks around turbocharger and EGR cooler
  • Check coolant level and DEF fluid level
  • Inspect air filter and intake system
  • Test glow plug system operation (cold start)
  • Check exhaust for excessive smoke
  • Inspect fuel water separator
  • Verify DPF status and regeneration cycle data

Heavy-Duty Brake Assessment

  • Measure brake pad/shoe thickness (minimum 4mm)
  • Inspect rotors/drums for scoring or heat damage
  • Check brake actuators and slack adjusters
  • Test air brake system (if equipped)
  • Verify parking brake operation under load
  • Measure brake pedal travel and firmness
  • Inspect brake lines for damage or leaks
  • Test ABS and traction control system function

Heavy-Duty Chassis Inspection

  • Inspect frame rails for cracks or damage
  • Check crossmembers and mounting brackets
  • Inspect suspension components under load
  • Check leaf springs and shackles for wear
  • Inspect steering components and linkage
  • Test shock absorbers and stabilizer bars
  • Check U-bolts and spring hangers
  • Verify proper axle alignment

Towing & Payload Systems

  • Inspect fifth wheel or gooseneck hitch
  • Check conventional hitch and receiver condition
  • Test trailer wiring and connections
  • Verify trailer brake controller function
  • Inspect bed and tie-down points
  • Check PTO system (if equipped)
  • Test integrated trailer brake system
  • Inspect weight distribution systems

Fleet Inspection Checklist

Verify the following components for each Super Duty truck in your fleet.

Powertrain Systems

  • Inspect automatic transmission fluid level and condition
  • Check for transmission leaks at pan and cooler lines
  • Test shift quality and TorqShift operation
  • Inspect transfer case fluid and operation (4WD)
  • Check driveshafts and U-joints
  • Inspect differential oil levels and condition
  • Check axle seals for leakage
  • Test engine performance under load

Heavy-Duty Electrical System

  • Test dual battery system voltage and condition
  • Check high-output alternator performance
  • Inspect starter motor operation
  • Verify upfitter switches and auxiliary circuits
  • Test all exterior lighting and signals
  • Check electronic instrument cluster function
  • Inspect fuse boxes and relay centers
  • Test auxiliary power outlets and inverters

Cooling & HVAC Systems

  • Pressure test heavy-duty cooling system
  • Inspect radiator and transmission cooler
  • Check engine fan clutch operation
  • Test auxiliary cooling systems (if equipped)
  • Verify A/C performance and refrigerant level
  • Inspect cabin heating system
  • Check auxiliary heater/AC systems
  • Test defroster function and blower operation

Super Duty Suspension

  • Inspect front coil springs and mounts
  • Check rear leaf springs and blocks
  • Test heavy-duty shock absorbers
  • Inspect stabilizer bars and links
  • Check Twin I-Beam suspension (F-250/350)
  • Inspect solid axle components (F-450/550)
  • Test suspension under load conditions
  • Verify ride height and leveling systems

Commercial Tires & Wheels

  • Check tire pressure in all positions
  • Inspect tread depth (minimum 6/32" front, 2/32" rear)
  • Look for uneven wear patterns or damage
  • Inspect dual rear wheel spacing and alignment
  • Check wheel condition and lug nuts (torque to spec)
  • Inspect valve stems and TPMS sensors
  • Check for proper tire rating for GVWR
  • Verify spare tire condition and accessibility

Steering & 4WD Systems

  • Check power steering fluid level and condition
  • Inspect steering gear and linkage
  • Test steering for free play and responsiveness
  • Check 4WD engagement and operation
  • Inspect front axle and hubs
  • Test electronic locking differential
  • Check transfer case controls and operation
  • Verify hill descent control system (if equipped)

Body & Upfit Inspection

  • Inspect cab and body panels for damage
  • Check upfit equipment and mounting points
  • Inspect utility bodies or flatbeds
  • Test power takeoff (PTO) systems
  • Verify proper function of dump beds or lifts
  • Check service body compartments and latches
  • Inspect welds and structural components
  • Test auxiliary lighting and power systems

Fleet Compliance & Documentation

  • Verify current registration and insurance
  • Check for completed DVIR forms
  • Inspect for required DOT markings
  • Verify annual inspection compliance
  • Check FMCSA documentation (if applicable)
  • Inspect required safety equipment
  • Verify emissions testing compliance
  • Check maintenance history records
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