Repair or Replace? How to Know What Your Hydraulic Cylinder Really Needs

In most cases, hydraulic cylinders can be repaired, but in some situations, a replacement might be the most cost-effective choice. Learn more.

Olivia Yates
July 21st, 2025
(Modified: August 13, 2025)
Cylinders

Hydraulic systems seldom fail without warning, and in almost every case where a hydraulic cylinder has stalled or is unable to hold a load, there were early warning signs.

If you’ve noticed unusual noises, overheating, leaks, juddering, slow operation, contamination, or other issues with your hydraulic cylinder, don’t delay. By delaying, you ultimately end up costing yourself more in the long run.

In most cases, hydraulic cylinders can be repaired, but every situation is unique.

When a Repair Is the Right Choice

The most common problems with hydraulic cylinders are relatively minor and can be easily repaired, especially when detected early. Some of the most common repairs include:

Leaks: These are often due to failing seals. Both the static seal around the head and the dynamic seal on the piston are inexpensive and straightforward to replace.
Inconsistent Motion: This issue can be caused by wear or scoring of the rod or faults in the pin or bushing. Again, these are usually straightforward repairs.

These faults seldom stop the cylinder from working completely, although safety concerns might prompt you to take it out of service immediately. In most cases, these types of repairs can be accomplished in just a few hours.

When determining if a repair is the right solution, consider:

The nature of the fault
Availability of replacement parts
Whether it’s possible to schedule downtime
How long will the cylinder be out of service

When It’s Time to Replace Your Cylinder

Replacements can be the best option in some scenarios, including:

When there is severe damage or too many components that need to be replaced. Examples of severe cylinder damage include cracks in the cylinder barrel and bent rods or severe corrosion, which can occur when the cylinder is used in a hostile environment, such as where there’s saltwater exposure.
When the cylinder is being used in a safety-critical application. If the cylinder is used in a safety-critical application, or operator safety depends on proper functioning, replacement is usually the best option. The same applies in applications demanding regulatory compliance: don’t take chances, just buy a new cylinder.
When the cost of the repair is more than half the cost of a new unit. This is a good rule of thumb when it comes to deciding between a replacement and a repair. Some organizations formalize this, while others treat it as a guide. However, the more expensive the repair, the more attractive a replacement can be.
When the cylinder is nearing the end of its expected service life. If either the cylinder or the equipment it’s used on is nearing the end of its life, a repair that provides a few additional months might be the preferred option. Alternatively, if a new cylinder will allow many more years of service from the equipment, replacement might be the better option.
When there is a better upgrade available. When a hydraulic cylinder has been in service a long time, it’s likely that there’s an upgraded model available. If this upgrade offers benefits like reduced mass or higher efficiency, replacement could yield savings in operating costs.

Key Factors to Consider Before You Decide

After having an expert assessment of the damage and extent of repair work needed, the factors to consider when deciding whether to repair or replace a hydraulic cylinder include:

The total cost of each option
The downtime expected from each option
The age of the cylinder
The repair history of the cylinder
The time needed to obtain replacement parts versus the lead time on a new cylinder

Schedule an Evaluation With Yates Cylinders Today

Not every scenario is black-and-white. If you’re experiencing issues with your hydraulic cylinder, your best bet is to schedule a professional evaluation.

Our experts at Yate Cylinders can help you decide whether a repair or a replacement is the most cost-effective option for you. We’re proud to be an industry-leading, U.S.-based manufacturer of tie rod, welded, and mill-duty cylinders, and a repair service provider.

Please contact us online to request an evaluation or call (800) 340-6024 now if you’re experiencing an emergency.