When to Repair or Replace Your Forklift

Quick Facts: Forklift Repair vs Replace

• Most forklifts last between 10,000–20,000 hours
• If breakdowns are frequent, it may be time to replace
• Repair bills that pile up usually signal deeper issues
• Newer forklifts can save money long-term with lower maintenance
• Thompson Lift Truck can help you figure out the smart move

So your forklift’s been giving you trouble again. Maybe it’s leaking fluid, maybe it won’t start, or maybe your team’s just tired of dealing with it. Either way, you’re probably asking: Should I fix it or finally invest in a new one?

That decision can be tricky. A repair might seem like the cheaper option, but if the breakdowns keep happening, or the costs keep stacking up, you could be throwing good money away.  On the flip side, replacing a forklift is a big move, and you don’t want to jump the gun.

Let’s look at a few simple ways to help you decide what’s worth fixing… and when it’s time to move on.

How Old Is Your Forklift, Really?

Age and hours both matter when it comes to forklift lifespan. Most machines are built to last somewhere between 10,000 and 20,000 hours, depending on how they’ve been used and maintained.

Still under 7,000 hours? A repair might be worth it, especially if it hasn’t had many issues before. But if it’s pushing 15,000 hours, and it’s starting to need repairs more often, it might be time to start thinking about a replacement.

And just because it runs doesn’t mean it’s doing the job well.

Is It Breaking Down Too Often?

Stuff happens, parts wear out, tires go bald, batteries die. But when you’re constantly fixing one thing after another, it adds up fast.

If your forklift is breaking down more than once every couple of months, or worse, every few weeks, it’s not just about the repair costs. You’re also losing time and productivity, which can slow down your whole operation.

Ask yourself: Are you making quick fixes, or are you keeping a worn-out machine on life support?

What’s the Real Cost of Maintenance?

One repair might be manageable. Two or three in a row? That’s a different story.

Take a minute and add up what you’ve spent on maintenance over the past 6 to 12 months. Include labor, parts, and service calls; the whole picture. If that number is close to half of what the forklift is worth, it’s probably smarter to put that money toward a new or gently used replacement.

Don’t forget the hidden costs, either: delays, rental fees while it’s being fixed, or lost productivity when things slow down.

Total Cost of Ownership (TCO) Matters More Than One Bill

Looking at one invoice doesn’t tell the whole story. What you really want to look at is the total cost of ownership, that means fuel (or electricity), maintenance, downtime, and efficiency over time.

Sure, a new forklift might cost more upfront. But it could save you money in the long run if it breaks down less, uses less energy, or comes with a warranty that covers early repairs.

Sometimes replacing a forklift isn’t just about fixing a problem; it’s about making your business run better.

Is It Still Safe and Efficient?

We all probably know: some forklifts still run even when they shouldn’t. Maybe the brakes are soft, the mast’s a little slow, or the seat wobbles. It still works, but that doesn’t mean it’s safe.

If your forklift is missing modern safety features, or if your operators are constantly working around “quirks,” it might be time to upgrade. Your team deserves equipment they can trust.

Need Help Deciding Whether to Repair or Replace Your Forklift? Let’s Figure It Out Together

Sometimes it’s clear what to do. Other times, it’s not so black and white. That’s why Thompson Lift Truck is here to help.

We can take a look at your equipment, your repair history, and your operation as a whole, then walk you through the pros and cons of repairing vs. replacing. No pressure, just honest advice.