The objective of this article is to investigate the rollover threshold of a heavy-duty vehicle during cornering. Based on the multi-body dynamics theory, a high-fidelity model is established, which takes account of the chassis flexibility, the suspension nonlinear characteristics, the tire handling model, and Ackermann steering strategy. Furthermore, by the inverse fast Fourier transform method, a three-dimensional stochastic road in space domain is employed in the model to improve the accuracy. A full-size heavy-duty vehicle test was carried out to validate the model. Based on the validated model, the rollover stability and rollover threshold of the heavy-duty vehicle during cornering are investigated. Lateral acceleration, yaw rate, roll angle, and vehicle torsional deflection in different cornering conditions are analyzed. The rollover threshold is summarized by the response surface methodology for the safe cornering purpose. The result shows the practical meaning of improving transportation safety of heavy-duty vehicles and also provides useful insights for developing the rollover warning system.