Forklift forks wear most at the heel, where they thin under load. Bent blades, a wrong blade-to-shank angle, surface cracks and a worn heel all reduce capacity and risk a dropped load. Inspect with calipers and an angle check, and remember worn forks are replaced, not welded.
Most likely causes
Heel wear — The fork heel thins under repeated load; about 10 percent thickness loss roughly halves the fork's safe capacity.
Bent blade or shank — Overloading or striking racking bends the blade or shank, throwing off the angle and load contact.
Surface cracks — Cracks at the heel or weld points can grow and cause sudden failure.
Worn or damaged locating latch — A worn positioning latch lets a fork slide or pop off the carriage.
How to diagnose it
1Measure heel thickness with calipers and compare to the shank — about 10 percent loss means replacement.
2Check the blade-to-shank angle, which should be about 90 degrees; more than about 3 degrees off means the fork is bent.
3Inspect for surface cracks, especially at the heel and welds, using a clean visual or dye-penetrant check.
4Confirm the fork tips are level and the difference between a pair is within tolerance.
5Check the locating/positioning latch holds the fork firmly on the carriage.
6Replace forks in matched pairs — never weld or heat-straighten load-bearing forks.
⚠ Safety: Forks are load-bearing safety components — never repair, weld or heat a worn or bent fork. Remove worn forks from service and replace them as a matched pair.
Parts that commonly fix this
FAQ
When should forklift forks be replaced?
Replace forks when heel wear reaches about 10 percent, the blade-to-shank angle is more than about 3 degrees off, or you find any cracks. Replace as a matched pair.
Can you weld or straighten a bent forklift fork?
No — load-bearing forks must never be welded, heated or straightened, as it weakens the steel. A bent or cracked fork is replaced.
Why is fork heel wear so important?
The heel carries the load; about 10 percent thickness loss can roughly halve the fork's rated capacity, so heel wear is the key inspection point.
How often should forklift forks be inspected?
Inspect forks regularly as part of routine checks, and at least annually by a competent person — daily visual checks catch obvious cracks and bends.
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Get a parts quote →Diagnostic guidance is general and indicative — always follow your truck's service manual and a qualified technician for your specific model.
