How to Replace Wear Pads on a Terex Telescopic Boom Wear pads on a Terex telescopic boom take constant friction as the boom extends and retracts. When they’re worn down, you’ll feel it right away: sections start binding, the extension feels rough, and metal surfaces begin to show scoring. Replacing the pads isn’t complicated, but it does require patience, safe setup, and parts that meet spec — ideally genuine, quality Terex parts. This walkthrough keeps things simple and grounded in what techs actually do on the floor. Start with safety and setup Any work on a telescopic boom begins with stabilizing the machine. Pull the key, isolate the battery, and release any hydraulic pressure. Make sure the boom is fully supported with slings or blocking before you loosen anything. Never trust the hydraulics t o hold a section in place; one drift or hose failure can turn a routine job into a dangerous one. Most techs also take a moment to lay out tools, pads, fasteners, and the service manual. Having everything within reach keeps the job steady and avoids rushing once the boom is opened up. Inspect the boom before taking it apart Before removing a single bolt, extend the boom slowly and watch how each section behaves. If a section hesitates or shifts sideways, note it. Photos help, too. Grab a few shots of the pad layout, shim positions, and bolt patterns. This isn’t busywork — it saves time during reassembly, especially if you haven’t worked on this exact model recently. It’s also a good moment to measure the pad thickness and compare it with the service limits. When they fall at or below the recommended minimum, replacement is the right call. Removing the old pads Once the boom is supported and documented, start loosening the pad fasteners. Most techs give the bolts a shot of penetrating oil first, especially on machines that work in harsh environments. Back the bolts out evenly rather than pulling one all the way w hile the others are still tight. Keeping the load even helps prevent pads from binding as they come off. If a pad refuses to move, a soft mallet and a small pry bar usually break it free. Avoid metal - on - metal strikes or sharp tools. Anything that gouges the boom surface will cause problems later, even if the damage looks minor. When the pad comes off, clean the area thoroughly. Old adhesive, rust flakes, and packed - in dirt are common. A clean surface will determine how well the new pad seats. Preparing the seating surface This step often gets rushed, but it’s the difference between a pad that lasts and one that wears out early. Wipe everything down with solvent and inspect the metal. Light corrosion is normal and easy to remove with a wire brush. Deep pitting, warping, or c racks need attention before you continue. Once the surface is clean and bare, dry it fully. Any leftover moisture or debris trapped under the pad will cause uneven wear and may throw the boom slightly out of alignment. Installing the new wear pads New pads should sit flush without rocking. Before tightening anything, position each pad exactly as the original sat, including its orientation and any shims. Hand - start the bolts to make sure threads engage cleanly. If the manual calls for anti - seize or threadlocker, follow it precisely — skipping or guessing here only creates more work later. Tighten the bolts gradually in the recommended pattern. Terex torque specs matter; eyeballing it isn’t good enough. Proper torque keeps pads from shifting under load and prevents fasteners from stretching or backing out. If a pad doesn’t sit flat after torquing, something’s off. Back up, clean the surface again, or check for debris under a shim. Forcing a pad into place never works out well. Testing the boom after installation Once everything is bolted down, retract the boom fully and cycle it a few times at low speed. Listen for scraping, clicking, or unusual resistance. The boom should move smoothly without hesitation. Many techs recheck the torque after a couple of cycles be c ause the pads sometimes settle slightly. While cycling, look at hydraulic lines, hoses, and wiring around the boom. Make sure nothing is now rubbing or sitting where it shouldn’t. It’s easy for a hose to shift during repair and start chafing once the boom moves under load. Write down the date, hours, pad part numbers, and torque values. Future you — or the next tech — will appreciate it. When things don’t go as planned Most wear pad jobs go smoothly, but a few issues come up often enough to mention. Pads that sit unevenly usually point to debris or damage on the mating surface. Fasteners that won’t torque often mean stretched bolts or damaged threads. Binding during exte nsion is almost always an alignment or support issue, so double - check your setup. If pads wear out again sooner than they should, you may be dealing with misalignment between boom sections or a pad material that doesn’t match Terex requirements. That’s where sticking with verified quality Terex parts makes a real difference; the tolerances are right, and the material matches factory specs. Final thoughts Replacing wear pads isn’t glamorous work, but it’s essential for keeping a telescopic boom healthy. The key is taking it slow, supporting the sections safely, cleaning the mating surfaces, and installing pads exactly as the manual specifies. A careful appr oach prevents binding, protects the boom sections, and keeps the machine running smoothly. If anything feels off at any stage, stop and reassess. On these machines, trust your hands, your eyes, and the service manual — in that order.