When to Replace Your CTL Tracks: 7 Warning Signs

A track blowout in the field is more than an inconvenience. It's lost productivity, emergency service calls, and potential damage to your undercarriage. The contractors who avoid these headaches are the ones who replace tracks before they fail.

Here are the seven warning signs that tell you it's time for new CTL tracks.

1. Visible Steel Cord Exposure

This is the clearest sign you're overdue. If you can see the steel cords through the rubber—anywhere on the track—stop running the machine.

Exposed cords mean the rubber compound has worn through completely. Water, dirt, and debris will now reach the internal structure, causing rust and rapid deterioration. A track in this condition can fail without warning.

Action: Replace immediately. Do not continue operating.

2. Cracking in the Tread or Sidewall

Surface cracks from age and UV exposure are normal. But deep cracks that extend into the carcass—the structural layer beneath the surface rubber—indicate the track is breaking down internally.

Pay special attention to cracks between the lugs, at the base of the lugs, and along the edges. These areas flex the most and fail first.

Action: If cracks are surface-level, monitor closely. If cracks reach the carcass, plan for replacement within 100-200 hours.

3. Missing or Damaged Lugs

One torn lug usually isn't a crisis. Multiple missing lugs affect traction, cause vibration, and put uneven stress on the undercarriage.

Look for lugs that are torn, chunked, or worn down to stubs. If more than 10% of your lugs are damaged, track performance is compromised.

Action: Replace when damage affects operation or traction. Monitor for progressive damage.

4. Track Slipping on the Sprocket

If your tracks are slipping even with proper tension, the drive lugs are worn. These are the internal lugs that engage with the sprocket teeth. When they're rounded or missing, the sprocket can't grip properly.

Slipping accelerates wear on both the track and sprocket. It also reduces pushing power and can make the machine unpredictable on slopes.

Action: Replace tracks before the slipping damages the sprocket.

5. Excessive or Uneven Wear

Check tread depth across the entire track. Wear should be relatively even from front to back. If you see:

• One side worn more than the other: Alignment issue or bent frame
• Front or rear worn faster: Tension problem or worn idler/sprocket
• Cupping or scalloping: Undercarriage component failure

Uneven wear means something else is wrong. Replacing tracks without fixing the underlying issue will just destroy the new set.

Action: Diagnose the cause before replacing. Fix undercarriage issues first.

6. Stretched Track (Won't Hold Tension)

Rubber tracks stretch over time. A small amount of stretch is normal and can be compensated with tension adjustment. But when you've maxed out the tensioner and the track is still loose, it's done.

A stretched track is more prone to de-tracking, slipping, and uneven wear. It also puts extra stress on the idler and tensioner assembly.

Action: Replace when you can no longer maintain proper tension.

7. Vibration or Rough Ride

Worn tracks cause noticeable vibration at the operator station. If your CTL suddenly feels rougher than usual—especially at speed—inspect the tracks.

Common causes include flat spots, missing lugs, internal cord damage, and delamination (where rubber separates from the cords). These issues usually get worse, not better.

Action: Inspect tracks for visible damage. Plan replacement if vibration is progressive.

How Much Life is Left?

A quick way to estimate remaining life is to measure tread depth:

• New track: 25-30mm tread depth (varies by model)
• 50% worn: 12-15mm tread depth
• Replace soon: Below 8-10mm tread depth
• Overdue: Cords visible or tread worn smooth

Track your hours between replacements. If you know your average track life is 1,800 hours, start planning replacement at 1,500 hours.

The Cost of Waiting Too Long

Running tracks to failure seems like you're getting your money's worth. In reality, it often costs more:

• Emergency service: Field repair costs 2-3x shop rates
• Undercarriage damage: A broken track can damage rollers, idlers, and the frame
• Lost productivity: Downtime waiting for parts and repair
• Safety risk: A sudden failure can injure the operator or bystanders

Replace tracks on your schedule, not the machine's.

The Bottom Line

Inspect your tracks weekly. Look for cord exposure, cracking, damaged lugs, and uneven wear. Check tension and watch for slipping or vibration. When you see multiple warning signs—or any single critical sign like cord exposure—it's time.

Keeping a spare set of tracks in your shop means you control when the swap happens. Waiting until failure means the job site controls you.