How to Replace Hydraulic Seals

Restoring a hydraulic cylinder to optimal performance involves a systematic approach to replacing hydraulic seals, which requires a blend of expertise, experience, and specialized equipment. Following the correct procedures from start to finish is crucial, with careful attention given to each step to maintain quality standards. Every cylinder provides evidence that can help identify the cause of its failure, which must be addressed to ensure proper functionality and prevent recurring issues. Neglecting any aspect of the process or mishandling components can lead to subpar performance, a shortened lifespan, or rapid failure.

With this in mind, although Automotive Lift Repair Orlando manufactures and distributes hydraulic seals but does not repair cylinders, we want to provide insight into the complete hydraulic cylinder repair process. We’ll illustrate what it takes to transform a worn-out cylinder into a nearly new component with performance comparable to when it left the factory.

 The Correct Hydraulic Cylinder Repair Process

Step 1: Disassembly  

The repair process begins with a careful disassembly of each cylinder, regardless of its size. Hydraulic seal repair shops often utilize heavy-duty overhead cranes and powerful disassembly rigs to handle large cylinders efficiently.

The disassembly procedure should be well-practiced, with cylinders properly prepared and secured. High-quality equipment is essential to ensure a controlled disassembly process and to prevent damage. Any damage during disassembly can raise repair costs and complicate the diagnosis of the actual cause of failure, making it difficult to differentiate between damage caused during the disassembly and that from regular operation.

Using appropriate rigs, tools, and meticulous procedures is a vital first step toward achieving a high-quality repair.

Step 2: Inspection & Evaluation  

Every Automotive Lift Repair Orlando cylinder undergoes a thorough investigation akin to a forensic analysis. An experienced technician examines the failed cylinder for indicators such as fractured, swollen, or glazed seals, scored or unevenly worn piston rods, ballooned barrel tubes, or cracked welds.

Using manufacturer specifications and years of expertise, the technician meticulously measures each component with precise digital and manual instruments to assess the cylinder’s condition, including bore, piston, gland and rod. Each part is evaluated to confirm it meets the required tolerances.

Any component that exceeds the tolerance limits for the cylinder type or does not meet the manufacturer’s specifications will be sourced or custom-machined in our fully equipped machine shops. Automotive Lift Repair Orlando maintains adequate stock levels of common cylinder components in our warehouses and has strong relationships with OEMs to source components directly from manufacturers as needed.

In some instances, improved parts and seals may be selected to enhance performance and longevity, such as choosing seals with higher heat or duro ratings if the cylinder shows signs of excessive seal fracturing.

Step 4: Designing Components & Running Reliability Simulations  

For rare or difficult-to-find parts that are either too expensive or take too long to obtain, The Automotive Lift Repair Orlando engineering team can custom-design components using advanced engineering software. This software includes reliability simulation capabilities that analyze part performance to ensure durability and effectiveness, ensuring that the re-engineered component matches or exceeds the original specifications.

Step 5: Machining, Welding & Reconditioning  

Automotive Lift Repair Orlando is equipped with advanced CNC milling machines, lathes, large-scale boring machines, automated honing stations, and other tools capable of producing replacement seals to factory specifications.

Any part that cannot be sourced cost-effectively from manufacturers or other sources can be fabricated on-site. For example, wipers and wear bands are often made in-house, significantly reducing costs and turnaround times.

Automotive Lift Repair Orlandor shops utilize welding techniques, such as aluminum bronze overlay and submerged arc welding, to restore worn clevis eyes, pistons, spigots, and other components before machining them back to original specifications.

Throughout this process, strict repair procedures and quality standards must be upheld to ensure that each reconditioned component complies with manufacturer specifications and design tolerances.

Step 6: Sandblasting of Barrels & Other Components  

Our large sandblasting facilities can handle barrel tubes, clevises, joints, and other components, effectively stripping away flaked paint and rust to prepare surfaces for painting.

Step 7: Hydraulic Cylinder Rod Restoration  

Piston rods are ground and restored to original specifications using advanced surface engineering processes, such as industrial hard chrome plating, sulphamate nickel plating, laser cladding, and high-velocity oxygen fuel spraying.

It’s important to find a shop that operates a fully equipped industrial hard chroming facility capable of accommodating components of various sizes, including long cylinder rods. The staff should possess decades of experience and expertise in the highly technical and challenging process of hard chroming, ensuring consistent high-quality chrome products and fast turnaround times, ultimately contributing to cost-effective repairs.

Step 8: Reassembly  

Experienced technicians utilize cranes and benches to reassemble each reconditioned cylinder, employing the same rigorous procedures and high-quality equipment used in disassembly. Care must be taken to ensure precise installation of tightly fitting parts. Avoiding damage or incorrect installation at this stage is crucial, as it can significantly affect performance and lead to premature wear and failure. Technicians should adhere to strict assembly procedures while maintaining cleanliness to prevent internal contamination and ensuring the proper handling of sensitive components like seals and glands.

Step 9: Testing  

Testing is essential to verify that the cylinder meets required specifications and can develop the correct pressure without failing. Automotive Lift Repair Orlando seals undergo testing to meet stringent standards, and repair shops should have advanced testing stations and tailored testing procedures.

Any issues with machining or reassembly will be identified during this critical phase.

Step 10: Painting & Finishing  

Once testing is complete and the assembly is approved, the final step is to apply a fresh coat of durable industrial paint. This protective layer ensures that the exterior matches the restored interior, signaling that the cylinder has successfully completed its refurbishment. It transitions from a worn-out component to one with many more years of reliable service ahead.

In many cases, a hydraulic cylinder in your vehicle can be repaired by simply replacing the pistons or seals inside it. However, there may be rare instances when you need to replace the entire cylinder. If that’s the case, it’s important to know how to properly remove the old hydraulic cylinder and install a new one.