Your forklift is the heartbeat of your operation. When it’s running smoothly, your workflow moves efficiently, orders get out on time, and your team stays productive. But when it starts breaking down repeatedly, slowing productivity, or draining your repair budget, the big question inevitably pops up:
Should you repair your forklift…or is it time to replace it?
It’s a question many businesses struggle with, and the answer depends on several key factors. Here’s a breakdown to help you make the smartest, most cost-effective decision for your fleet.
1. How Old Is Your Forklift?
Much like cars, forklifts have a reliable “useful life.” Most units last 10,000 to 12,000 operating hours, though well-maintained equipment from brands like Toyota, Crown, and Clark can often go beyond that. Still, once you cross that threshold, expensive component failures become more likely.
If your forklift has high hours and continues to rack up costly repairs, replacement becomes the smarter long-term investment.
2. Frequent Breakdowns = Lost Productivity
Every hour a forklift is out of service impacts your team’s ability to get work done. Even a “simple fix” can mean:
- Disrupted workflow
- Delayed orders
- Extra labor costs
- Slower production
If your unit is breaking down more than 2–3 times per year or repairs seem to be increasing, it’s a strong sign the truck is nearing the end of its useful service life.
3. The 50% Rule: A Simple Guideline
A common industry guideline is:
If a repair will cost more than 50% of the forklift’s value, it’s time to consider replacing it.
Major repairs – like transmissions, motors, or hydraulic components – can hit that mark quickly, especially on aging equipment.
4. Don’t Forget About Battery Replacement
For electric forklifts, the battery is one of the most expensive components. Replacing it can be a major investment – sometimes several thousand dollars.
If your forklift is already older or has high hours, installing a brand-new battery may not be the best use of your budget. After the battery is replaced, the rest of the forklift is still aging, and other costly issues – motors, hydraulics, electronics – are more likely to appear.
In many cases, especially with older units, it makes more financial sense to invest in a newer forklift rather than putting a new battery into a machine that’s approaching the end of its lifecycle.
5. Safety Should Always Be the Deciding Factor
If your forklift is consistently having issues with brakes, steering, hydraulics, or mast components, it presents a potential safety risk to your operators.
If your team no longer feels confident using a particular unit – or if safety-related repairs keep recurring – replacement isn’t just the smart choice; it’s the responsible one.
6. Technology & Efficiency Matter
Newer forklifts offer major improvements, including:
- Advanced safety features
- Better ergonomics
- Improved visibility
- Enhanced energy efficiency
- Longer battery life
- Cleaner operation
If your forklift lacks these advantages and struggles to keep up with your workload, upgrading can significantly boost productivity and operator comfort.
7. Repair Still Makes Sense When…
Repairing may be the right choice when:
- Your forklift is still fairly new
- Hours are on the lower side
- Maintenance has been consistent
- The issue is isolated
- The repair cost is reasonable
Routine maintenance – brakes, tires, PMs – is completely normal and not a sign of deeper issues.
8. Replacement Pays Off When…
You may want to consider investing in a new (or quality used) forklift if:
- Downtime is becoming too frequent
- Repair costs keep climbing
- Major components are failing
- Safety concerns keep resurfacing
- The forklift no longer meets performance needs
- The battery needs replacing on an older electric forklift
- Productivity is being affected
A newer unit often pays for itself in uptime, reliability, and long-term savings.
Not Sure Whether to Repair or Replace? Thompson & Johnson Can Help.
Every operation is different, which is why choosing to repair or replace should be based on a mix of cost, safety, performance, and long-term planning.
At Thompson & Johnson Equipment, we help businesses every day evaluate their fleets, understand repair costs, and identify the right time to upgrade. Whether you’re looking for:
- Dependable service and repairs
- Preventative maintenance support
- A quality new or used forklift
- Help planning and managing your fleet
We’re here to support you.
And if you’re considering purchasing a forklift, you’ve got options.
We offer flexible leasing programs, a strong selection of quality used forklifts, and short- and long-term rentals to fit the needs of any operation. Whatever your goals or budget, we’ll work with you to find a solution that fits you best.
If you’re weighing repair vs. replacement, reach out to us. Our team will guide you to the smartest, safest, and most cost-effective decision for your business.
Contact us today to schedule a repair or explore equipment options.
WE’RE HERE TO HELP
At Thompson & Johnson, we’re your full-service material handling partner. Whether you’re looking to buy forklifts or other equipment, purchase industrial batteries and chargers, find parts for all makes and models, enroll in a planned maintenance program, rent or lease from our wide selection of material handling equipment, or provide comprehensive forklift training for your operators, we’ve got you covered. Contact us today at (800) 589-5558 or via our Contact Us Form to get expert guidance tailored to your operation.
🛠️ Forklift Parts & Service – including tire replacement and maintenance
🚜 New & Used Forklifts – choose the right equipment for your operation
🔄 Forklift Rentals – flexible options when you need equipment fast
🎓 Operator Training Programs – extend tire life and improve safety with certified training
