If your pallet jack feels harder to push, leaves marks or "thumps" every few feet, worn wheels are usually the cause. To fix it: find out whether you need steer wheels or load wheels (the rollers under the forks), pick the material that suits your floor, measure diameter, width and bore before ordering, then swap them. This guide covers each step. If you keep spares on hand, you can browse our parts collection.
Which wheels are which?
"Pallet jack wheels" can mean either set, so confirm which one you need before ordering.
| Part | Where it is | Also called |
|---|---|---|
| Steer wheel | Near the handle; does most of the turning | Rear wheel, drive wheel on electric trucks |
| Load wheel | Under the forks; carries the pallet | Roller, front wheel, fork wheel |
| Tandem load wheels | Two wheels per fork instead of one | Dual rollers; smoother over gaps and thresholds |
Why wheels matter
Wheel material and condition affect push force and operator fatigue, noise, floor marking, how well the truck rolls over rough floors and debris, and how often it needs repair. Wheels take constant abuse from concrete seams, dock plates, debris and overloaded pallets. In a busy operation they are a wear item, so keeping spares in stock is normal maintenance. If pushing loaded pallets is wearing your team out, an electric pallet jack removes most of that effort.
Wheel materials and how to choose
There is no single best wheel. The right choice depends on your floor, environment and daily workload.
| Material | Best for | Trade-off |
|---|---|---|
| Polyurethane | Smooth indoor concrete and finished floors; quieter, less likely to mark | Can wear faster on rough pavement or debris-heavy docks, depending on the compound |
| Nylon | Rougher floors, wet or debris-prone areas; hard and durable | Noisier, and more likely to mark some floors |
| Rubber / non-marking rubber | Uneven surfaces and floor protection | Usually carries less load and may wear faster under heavy use |
| Steel / special duty | Niche environments with heat, chemicals or extreme abrasion | Loud and harsh on floors; not an everyday warehouse choice |
| Polyurethane on iron core | Higher duty cycles and heavier daily use | Costs more than a plain polyurethane wheel |
Most of Raelon's electric pallet jacks run on polyurethane wheels built for smooth indoor floors. The MN-01 all-terrain model uses a wheel setup built for rough or uneven ground instead. If floor protection is the priority, rubber is the usual choice, and non-marking rubber is the safest pick for finished floors.
Steer wheels or load wheels?
Choose by the problem you are fixing. If the truck is hard to turn, squeaks while steering or wobbles at the handle, start with the steer wheels and bearings. If the pallet feels bumpy, the forks chatter over seams or the truck struggles over dock plates, start with the load wheels. Tandem load wheels often smooth out gaps and thresholds.
A polyurethane roller set is a practical replacement for worn pallet truck wheels when the dimensions and bearing size match your equipment. Raelon sells the PU Pallet Truck Roller Set (6204) as a single wheel or with the bearing already fitted.
How to measure so you order the right wheel
Most wrong orders happen here: two wheels can look similar but have different bore sizes or widths. At minimum, measure:
- Wheel diameter
- Wheel width
- Axle or bearing inner diameter (bore size)
- Hub length or overall wheel assembly width
- Whether you need a single or tandem load wheel style
If you stock wheels for several trucks, label each kit with its measurements and the compatible model. It saves time when a wheel fails mid-shift.
How to change pallet jack wheels, step by step
The exact method depends on the model: some use snap rings, some roll pins and some axle bolts. Before you start, unload the truck, park on a flat surface and block it so it cannot roll. Wear gloves and eye protection, and if you are not comfortable lifting the truck safely, have a maintenance technician do it. The same process applies to manual and electric trucks.
- Confirm which wheels you are replacing: steer, load, or both. With tandem load wheels, replacing in pairs keeps rolling behaviour consistent.
- Lift and support the truck so the wheels are off the ground, by tilting it back and supporting the forks or using a stable jack stand setup. Do not rely on a loose block of wood.
- Remove the retaining hardware: snap ring (use snap ring pliers), roll pin (drive out with the correct punch) or axle bolt. If unsure, take a photo first.
- Slide out the axle and remove the wheel. On older trucks, light tapping with a punch can free a stuck axle. Check the axle, bearings, spacers and washers for wear, and keep the parts in order.
- Install the new wheel, slide the axle back through and refit the retaining hardware. Grease only if the wheel design calls for it.
- Repeat and test. Replace the other wheel in the pair if applicable, lower the truck and do a slow test roll with no load. Check for wobble, unusual noise and straight tracking. If anything binds, recheck the spacers, washers and axle alignment.
Not sure which wheels fit your truck?
Send us your truck model and the wheel diameter, width and bearing or bore size. We can help you identify the right steer wheels, load wheels or roller set before you order.
Replace a kit instead of a single wheel?
Sometimes the wheel is not the only worn part. If the axle is worn, the bearings are damaged or spacers are missing, replacing a complete wheel kit is usually faster and more reliable than rebuilding one part at a time.
Do worn wheels affect safety?
Yes. A truck that pulls to one side, binds in turns or has chunked load wheels is more likely to cause strains and foot injuries. Wheel upkeep is one part of parts planning; batteries and chargers matter on electric trucks too. Our pallet jack parts guide covers what wears out first and when to repair, call for service or replace the unit.
Common questions
How do I know which wheels my pallet jack needs?
Pallet jack wheels can mean either set, so confirm which one you need before ordering. Steer wheels are near the handle and do most of the turning. Load wheels are under the forks and carry the pallet. If the truck is hard to turn, squeaks while steering or wobbles at the handle, start with the steer wheels and bearings. If the pallet feels bumpy, the forks chatter over seams or the truck struggles over dock plates, start with the load wheels.
What are the best pallet jack wheels for my floor?
There is no single best wheel. Polyurethane suits smooth indoor concrete and finished floors, and is quieter and less likely to mark. Nylon suits rougher, wet or debris-prone areas, but is noisier and more likely to mark some floors. Rubber suits uneven surfaces and floor protection, and non-marking rubber is the safest pick for finished floors.
How do I measure for replacement pallet jack wheels?
Most wrong orders happen here, because two wheels can look similar but have different bore sizes or widths. At minimum, measure the wheel diameter, the wheel width, the axle or bearing inner diameter (bore size), the hub length or overall wheel assembly width, and whether you need a single or tandem load wheel style.
How do I change pallet jack wheels?
The exact method depends on the model: some use snap rings, some roll pins and some axle bolts. Unload the truck, park on a flat surface and block it so it cannot roll. Lift and support the truck so the wheels are off the ground, remove the retaining hardware, slide out the axle and wheel, fit the new wheel, refit the hardware, then do a slow test roll with no load. If you are not comfortable lifting the truck safely, have a maintenance technician do it.
Should I replace a single wheel or a whole wheel kit?
Sometimes the wheel is not the only worn part. If the axle is worn, the bearings are damaged or spacers are missing, replacing a complete wheel kit is usually faster and more reliable than rebuilding one part at a time.
Floor conditions and workload decide your wheel choice, so before planning a fleet upgrade, ask what floors you run on daily and whether you need non-marking wheels.
See what people are saying
1 Comment
Hello! We need to purchase a pallet jack for outdoors. We are a cemetery and we need to move stored monuments. Do you recommend any particular unit, and what about t...
Hello! We need to purchase a pallet jack for outdoors. We are a cemetery and we need to move stored monuments. Do you recommend any particular unit, and what about the tires? Can we use this outdoors? Thanks. Steve
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