PA Inspection Failure Statistics
Approximately 15-20% of Pennsylvania vehicles fail their initial safety inspection. The good news: most failures involve inexpensive, easy-to-fix issues.
The Top 10 Inspection Failure Reasons
1. Lighting System Failures (35-40% of All Failures)
Burned-out bulbs, non-functional turn signals, and dim headlights are the easiest to prevent.
Cost to Fix: DIY: $5-30 | Professional: $25-75
2. Tire Tread Depth and Condition (15-20%)
Pennsylvania requires minimum 2/32" tread depth. Check with the penny test.
Cost to Fix: $100-200 per tire
3. Brake System Issues (12-15%)
Worn brake pads, damaged rotors, parking brake failure.
Cost to Fix: Pads: $150-300 per axle | Major repairs: $500-1,200
4. Windshield Damage (10-12%)
Cracks longer than 11 inches or damage in driver's critical view.
Cost to Fix: Chip repair: $50-100 | Full replacement: $200-500
5. Windshield Wiper Failures (8-10%)
Torn, cracked, or streaking wiper blades.
Cost to Fix: DIY: $15-40 | Professional: $30-60
6. Check Engine Light / Emissions (8-10%)
In 25 emissions counties, an illuminated check engine light means automatic failure.
Cost to Fix: Gas cap: $15-30 | O2 sensor: $150-400 | Catalytic converter: $400-2,500+
7. Steering and Suspension Problems (5-8%)
Excessive steering wheel play, worn ball joints or tie rods.
Cost to Fix: Ball joints: $200-400 | Struts: $400-900 per axle
8. Exhaust System Leaks (5-7%)
Holes, rust-through, or loose hangers.
Cost to Fix: Pipe repair: $100-300 | Complete system: $500-1,500
9. Horn and Seatbelt Issues (3-5%)
Non-functional horn or seatbelts that don't retract.
Cost to Fix: Horn: $20-150 | Seatbelt: $150-400
10. Body and Frame Integrity (2-4%)
Excessive rust, doors that won't latch, sharp body damage.
Cost to Fix: Minor rust: $200-600 | Major work: $1,000-5,000+