DVSA Releases Key Changes to HGV MOT Inspection Manual
The DVSA released a comprehensive update to the HGV Inspection Manual, with changes coming into effect from 1st April 2025. These revisions introduce greater clarity and more robust testing standards, with key updates across multiple sections of the manual.
All operators, transport managers, and technicians should familiarise themselves with the updated content to remain compliant and ensure vehicles meet the new inspection criteria. Below is an overview of the most significant changes introduced in the revised guidance.
📘 Link to the updated manual:
HGV Inspection Manual – From 1 April 2025 (GOV.UK)
Tyres – Section 7
On page 10, an amendment has been made to clarify the definition of a dangerous tyre defect. Specifically, under Deficiency 1a (ii), tyres that are overloaded by at least 10% beyond their load index or ply rating are now explicitly classed as a dangerous defect.
New wording includes:
"...and is loaded at least 10% in excess of the tyre load index/ply rating."
This update provides clearer criteria for inspectors and operators, reinforcing the importance of correct tyre specification.
Sideguards and Rear Underrun Protection – Section 9
This section has been completely rewritten for better structure and comprehension. The revision includes:
An updated list of vehicles exempt from sideguard requirements (effective from 01/04/25).
New imagery to illustrate correct sideguard positioning and lateral projection.
Additional information on BSIS radar sensors fitted in sideguard gaps.
This overhaul enhances visual understanding and aligns test procedures with modern vehicle technologies.
Glass and Driver Visibility – Section 23
A monitor for indirect vision systems has now been added to the list of acceptable items that may intrude into the driver’s field of view (within the swept area of windscreen wipers), provided it doesn’t significantly hinder visibility.
Other acceptable items include:
Fresnel lenses
Toll tags
Blinds and mountings
Split windscreens
Driver monitoring systems
This update recognises the increasing use of digital driver aids in modern HGVs.
Brake System Pressure/Vacuum Build-Up – Section 34
Clarification has been added for vehicles designed to tow trailers. The maximum acceptable pressure build-up time of six minutes now applies whether a trailer is attached or not.
This ensures a consistent inspection approach, regardless of whether the towing vehicle is coupled at the time of test.
Fuel Systems – Section 45
Hydrogen fuel cell tanks are now explicitly included within the definition of testable fuel tanks. Updates also cover:
LPG, CNG, and LNG systems.
Testing procedures for corrosion and damage.
This broadens the scope of inspections to include a wider range of alternative fuel technologies, ensuring continued safety as fleets adopt cleaner fuel sources.
Brake Pipes – Section 59
Brake pipes showing more than one-third loss of original wall thickness are now classed as either major or dangerous defects, depending on severity.
This update strengthens safety standards around brake component integrity and highlights the importance of regular inspections.
Brake Performance and Load Simulation – Section 71
Changes include:
Vehicles should be presented loaded where possible. If not, a load simulator can be used.
For certain vehicles (e.g. three-axle tractors), testing must be done with a loaded trailer to achieve accurate drive axle weight (at least 65% of design axle weight).
For vehicles with Load Sensing Valves (LSVs), the vehicle must be loaded for proper operation. If this isn’t possible, temporary disconnection is permitted—but the driver must reconnect it before leaving the test site.
These clarifications help ensure that brake testing reflects real-world conditions.
Final Thoughts
The April 2025 MOT manual revisions reflect the DVSA’s ongoing commitment to improving road safety and standardising test procedures. Operators are encouraged to:
Review their inspection preparation processes.
Update technician and driver training materials.
Conduct internal audits to ensure readiness for the new standards.
By staying ahead of regulatory changes, transport businesses can protect their operator licence, improve vehicle safety, and demonstrate a commitment to compliance and professional standards.
If you need support understanding how these updates affect your operation, or if you’d like assistance delivering training to your staff, get in touch with us at Dynamic Consultancy Solutions.