Replacing a caster starts with identifying its mount type (plate or stem) and exact dimensions, then matching or upgrading capacity and wheel material — don't assume a caster that "looks about right" will actually fit or perform the same.
If the old caster failed under normal use, consider whether the failure points to needing a capacity upgrade or a construction change (like moving to kingpinless) rather than just an identical replacement.
Any time an existing caster fails, wears out, or no longer performs adequately.
Replacing like-for-like without asking why the old one failed. If it failed from shock or high-cycle wear, an identical replacement may just fail the same way again — consider a capacity or construction upgrade instead.
Should I always replace with the exact same caster?
Not necessarily — if the old one failed prematurely, consider whether a capacity upgrade or different construction (like kingpinless) would hold up better.
What should I measure before ordering a replacement?
Mount type and dimensions first (see how to measure a caster), then capacity and wheel material.