BLT Checklist: How brakes, lights, and tires keep your equipment reliable

While CVSA Brake Safety Week is behind us, these areas still deserve extra focus. But in reality, they’ve been in the spotlight since International Roadcheck kicked off back in May, and they remain critical every day.

Putting safety on the front burner

Truck safety continues to dominate the conversation, and the numbers speak for themselves. The National Highway and Transportation Safety Administration (NHTSA) reports that large truck crashes claim more than 5,000 lives annually.

Tracking BLT-related issues is no longer optional—it’s essential. Organizations with transportation fleets are now benchmarking CSA (Compliance, Safety, Accountability)  scores against fleet-specific KPIs, according to the latest TRUST Safety Index. Among top private fleets, violations broke down as follows: tires (50%), brakes (33%), and lighting (17%). And the 2025 NPTC Benchmarking Survey confirms the pattern, with breakdown causes led by tires (48%), brakes (25%), and lights (14%).

Brake care basics

Brake systems are at the heart of fleet safety. From drums and rotors to lines and hoses, every part matters. Cracks, rust, or heavy wear all threaten stopping distance, which regulations have reduced from 355 feet to less than 250 feet for a loaded three-axle tractor.

Proper brake inspections must look at the entire system, not just one component. Maintenance teams and drivers should pay attention to fluid levels, pedal feel, and wear surfaces. Rusted or grooved rotors and drums are red flags that require immediate attention. Staying ahead of issues not only keeps trucks compliant but also prevents accidents and saves lives.

Shining a light on inspections

Lighting is often one of the fastest ways to earn a violation. Because lights are either working or not, inspectors catch these problems quickly. Worse, a blown bulb can trigger a deeper inspection of the entire truck.

To combat lighting violations, fleets can help drivers by ensuring lights are part of every pre- and post-trip inspection. Headlights, brake lights, turn signals, and reflectors should all be checked. Maintenance programs should schedule lighting inspections, and cleaning lamps regularly can prevent issues. Wiring and connectors must also be monitored, as corrosion from road salt is a common culprit.

For LED systems, even a single dark diode can cause a violation. By following these best practices, fleets can significantly reduce lighting-related safety violations and the resulting impact on CSA scores and operational costs. 

While LED lights may be standard in many applications, the industry is still slowly phasing out incandescent bulbs. There are many benefits to specing an asset with LED or retrofit an older incandescent fleet to LED bulbs. LEDs use 90% less energy than standard bulbs, which slightly decreases fuel consumption. LEDs are brighter and more responsive than incandescent, which may decrease the chance of a rear end collision.

Tire talk

Tires are often overlooked until something goes wrong, but they’re also one of the leading causes of violations and breakdowns. Choosing the right tire for each application pays off in better uptime and fuel economy.

Air pressure is critical—underinflated tires burn more fuel, wear faster, and risk blowouts. Technicians should check pressure with a calibrated gauge, not outdated methods like striking the tire with a hammer.

DOT requirements call for 4/32nds tread on steer tires and 2/32nds on others. Regular monitoring prevents out-of-service orders, costly fines, and unnecessary downtime.

Turning data into action

Having all of this knowledge is one thing, making it actionable for the benefit of your organization is another. Advanced analytics allow organizations to predict issues before they lead to breakdowns. With the help of asset management partners, managers can build replacement strategies based on total cost of ownership, fuel economy, and maintenance trends.

Think of data as the mayonnaise—it brings the whole BLT together.