Replacing Grousers on the Case 850G and the Economics of Undercarriage Repair

[MikePhua]

The Case 850G and Its Undercarriage Design
The Case 850G Long Track dozer is a mid-size crawler tractor built for grading, site prep, and light earthmoving. Introduced in the late 1990s, the 850G featured hydrostatic drive, a six-way blade, and a long-track undercarriage for improved stability and traction. Case Construction Equipment, founded in 1842, has long been a leader in dozer innovation, and the 850G became a popular choice for contractors needing a balance of power and maneuverability.
Its undercarriage includes track chains, sprockets, rollers, and track pads fitted with grousers—raised steel bars that provide grip and traction. Over time, these grousers wear down, especially on hard surfaces or during aggressive grading. When they lose height and edge definition, traction suffers and fuel efficiency drops. Replacing them becomes a necessary investment in performance and safety.
Cost Breakdown for Grouser Replacement
Replacing worn grousers on a Case 850G can be done in two primary ways: replacing the entire track pad or welding new grouser bars onto the existing pads. Each method has its own cost structure and labor demands.
Estimated costs for full pad replacement:

• New aftermarket pads: $40–$70 per pad
  
• Quantity: Approximately 76 pads per side (152 total)
  
• Total parts cost: $3,000–$5,000
  
• Labor: $800–$1,200 depending on shop rates
  
• Hardware (bolts and nuts): $200–$400
  

Total estimated cost: $4,000–$6,600
This assumes use of aftermarket parts, which are widely available and often identical in fit and performance to OEM components. The Case part number for the 18-inch pad is 178445A1, and many suppliers offer bulk pricing for full sets.
Regrousering as a Cost-Saving Alternative
Instead of replacing the pads, many operators opt to weld new grouser bars onto the existing pads. This process, known as regrousering, involves cutting and fitting manganese steel bar stock onto the worn surfaces and welding them in place.
Advantages of regrousering:

• Lower material cost: Grouser bar stock is inexpensive
  
• Preserves original pad fitment and bolt pattern
  
• Can be done in-house with skilled labor
  

Challenges include:

• Labor-intensive: Requires cutting, fitting, and welding each bar
  
• High energy consumption: Welding hundreds of inches of steel
  
• Corner wear: Pads often wear unevenly, requiring filler or shaping
  
• Welding technique: 7018 stick or dual-shield wire recommended
  

If done in-house, regrousering can cost as little as $1,500–$2,000 in materials and consumables. Hiring it out may approach the cost of full pad replacement, making it less attractive unless downtime is critical.
Choosing the Right Grouser Stock
Manganese steel is the preferred material for grouser bars due to its hardness and resistance to abrasion. Suppliers like Dura-Tuff offer pre-curved grouser stock designed to match the contour of worn pads, reducing prep time and improving weld quality. While slightly more expensive than straight bar, curved stock saves labor and ensures consistent traction geometry.
Operators should consider:

• Bar height: Typically 1" to 1.5" depending on terrain
  
• Width: Must match pad surface without overhang
  
• Curvature: Reduces corner gaps and weld distortion
  
• Supplier reputation: Durability varies by brand
  

Dura-Tuff, based in Salt Lake City, is one of the few suppliers approved by Caterpillar for regrousering services. Their curved bar stock is widely used in forestry and mining applications where traction is critical.
Installation Tips and Field Wisdom
Whether replacing pads or welding new bars, attention to detail matters:

• Clean pad surfaces thoroughly before welding
  
• Use preheat if ambient temperature is below 50°F
  
• Stagger welds to reduce warping
  
• Torque bolts to spec and use new hardware
  
• Inspect sprockets and chains for compatibility
  

One technician in Arkansas noted that regrousering saved his crew nearly $3,000 on a seasonal rebuild. However, he emphasized the importance of cutting corners evenly and using filler rod to maintain pad geometry.
Conclusion
Replacing grousers on a Case 850G is a significant but necessary investment in traction and performance. Whether opting for full pad replacement or regrousering, the decision depends on budget, labor availability, and long-term usage plans. With aftermarket parts and quality grouser stock, operators can restore grip and extend undercarriage life without breaking the bank.