Pallet jack load wheels take a beating. Every pallet, every uneven warehouse floor joint, every overloaded skid puts stress on the small wheels at the front of the forks. When they wear out, a pallet jack that used to roll smoothly starts to feel like hard work — and it can damage floors, pallets, and even the jack itself.
Signs Your Load Wheels Need Replacing
- Flat spots or chunks missing from the wheel surface
- Cracked, split, or badly worn polyurethane or nylon tread
- Wobbling or uneven rolling under load
- Excessive noise or vibration while pushing or pulling
- Bent axles or worn bearings causing the wheel to drag
- Visibly smaller wheel diameter compared to a new one (from wear)
Load Wheels vs. Steer Wheels: Know the Difference
Pallet jacks have two sets of wheels: larger steer wheels at the back near the handle, and smaller load wheels (also called tandem wheels) at the front of the forks that carry the actual weight of the pallet. This guide focuses on load wheels, since they wear out faster due to the direct load they carry.
Tools You'll Need
- Socket set or wrench set (size depends on your jack model)
- Hammer or mallet, and a punch for stubborn axle pins
- Replacement load wheels matched to your pallet jack's fork width and axle size
- Grease for the new wheel bearings, if not pre-packed
Step-by-Step Load Wheel Replacement
- Raise and secure the forks. Pump the jack up so the wheels are off the ground, and block the forks so they can't drop while you work.
- Remove the retaining clip or cotter pin holding the wheel axle in place at the fork tip.
- Drive out the axle using a punch and hammer, supporting the wheel as it comes free so it doesn't drop.
- Remove the old wheel and bearings from the fork, noting the order of any spacers or bushings.
- Clean the axle bore in the fork tip and inspect it for wear, rust, or damage before installing the new wheel.
- Position the new load wheel in the fork, aligning it with the axle bore and replacing any spacers in the original order.
- Insert the new axle through the fork and wheel, tapping it through evenly with a hammer.
- Secure the axle with a new retaining clip or cotter pin — don't reuse a worn one.
- Lower the jack and test. Roll it under load and confirm both load wheels turn freely and evenly with no wobble.
Ordering the Right Wheels the First Time
Load wheels come in different materials (polyurethane, nylon, rubber) and diameters, and the right choice depends on your floor surface and load weight. Measure the old wheel's diameter and axle bore, or check your pallet jack's model number, before ordering to make sure the replacement is a direct fit.
Replace Both Wheels Together
Load wheels are almost always sold and worn as a matched pair. If one is damaged, the other has likely absorbed similar wear even if it looks fine — replacing both at once keeps the jack rolling evenly and saves you from doing the job twice.
Shop our full lineup of pallet jack and forklift wheels at JDLIFT PARTS - Wheels/ Tires.
Always block or secure the raised forks before working underneath, and consult your pallet jack's manual for exact axle and wheel specifications.