Replacing Track Pads on Crawler Equipment Without the Headache

[MikePhua]

The Function and Anatomy of Track Pads
Track pads, also known as track shoes, are bolted to the track chains of crawler machines such as dozers, excavators, and track loaders. Their primary role is to distribute the machine’s weight, provide traction, and protect the undercarriage from excessive wear. Depending on the application, pads may be single grouser (for aggressive traction), double grouser (for balance between grip and maneuverability), or triple grouser (for smoother travel and reduced ground damage).
Each pad is secured with high-torque bolts and lock nuts, often torqued to over 400 ft-lbs depending on the machine size. The pads themselves are typically made of hardened steel, though rubber-padded variants are used in urban or sensitive environments. Over time, pads wear down, crack, or loosen, requiring replacement to maintain performance and safety.
When to Replace Track Pads
Signs that track pads need replacement include:

• Excessive wear reducing grouser height
  
• Cracks or breaks from impact or fatigue
  
• Missing bolts or pads entirely
  
• Uneven wear causing vibration or instability
  
• Reduced traction in normal operating conditions
  
• Damage to adjacent components like track links or rollers
  

A forestry crew in Oregon noticed their excavator slipping on wet slopes. Inspection revealed that half the pads had worn below spec, compromising grip. Replacing them restored stability and reduced fuel consumption by 12% due to improved traction.
Tools and Setup for Efficient Replacement
To replace track pads safely and efficiently, prepare:

• Impact wrench or torque wrench rated for high torque
  
• Socket set matched to pad bolt size (often 1-1/8" or larger)
  
• Breaker bar for stubborn bolts
  
• Anti-seize compound for reinstallation
  
• Wire brush or grinder to clean bolt holes
  
• Jack stands or cribbing to stabilize the machine
  
• Safety gear including gloves, eye protection, and steel-toe boots
  

Some operators use a pneumatic impact gun with a torque stick to speed up removal. Others prefer manual torque wrenches for precision, especially when reassembling.
Step-by-Step Replacement Process

1. Park the machine on level ground and engage safety locks
   
2. Raise the track slightly using the blade or boom to relieve pressure
   
3. Remove old pads one at a time to avoid destabilizing the track
   
4. Clean bolt holes and inspect threads for damage
   
5. Apply anti-seize to new bolts and align new pad holes
   
6. Torque bolts to manufacturer spec (typically 350–450 ft-lbs)
   
7. Repeat across the entire track, checking alignment periodically
   
8. Lower the machine and test movement for vibration or noise
   

A contractor in Texas replaced all pads on a D6 dozer in under six hours using a rotating team of two mechanics and a mobile air compressor. They staggered pad removal to maintain track tension and avoided overloading any section.
Common Challenges and Solutions

• Frozen bolts: Use penetrating oil and heat to loosen. Avoid shearing by applying gradual torque.
  
• Misaligned holes: Check pad orientation and track tension. Loosen adjacent pads if needed.
  
• Stripped threads: Tap or chase threads with a die. Replace bolts if damage is severe.
  
• Pad rocking: Ensure full contact with the chain and torque evenly.
  
• Bolt fatigue: Replace bolts in sets to avoid uneven stress distribution.
  

One operator in Manitoba discovered that aftermarket pads had slightly different hole spacing. After drilling a custom jig and modifying the bolt pattern, the pads fit perfectly and held up through two seasons of grading.
Preventive Maintenance and Inspection Tips
To extend pad life:

• Inspect pads weekly for cracks, wear, and bolt tightness
  
• Retorque bolts after the first 10 hours of use post-installation
  
• Avoid high-speed travel on rocky terrain
  
• Use appropriate pad type for the job (e.g., single grouser for slopes, triple for pavement)
  
• Clean mud and debris from pads to prevent accelerated wear
  

A mining fleet in Chile implemented monthly pad inspections and reduced pad-related downtime by 40% over a year.
Conclusion
Replacing track pads may seem tedious, but with the right tools, preparation, and technique, it becomes a manageable task that pays dividends in machine performance and safety. Whether you're maintaining a compact track loader or a full-size dozer, each pad is a link in the chain of productivity. Treat them with care, and your machine will return the favor—one bolt at a time.