Hydraulic cylinders are among the most heavily worked components in any industrial system. When one starts to leak, operators face a decision: reseal or replace?
At first glance, replacement may seem like the simplest solution. But in many cases, a hydraulic cylinder reseal can restore full functionality at a fraction of the cost—provided the decision is made early.
This guide explains how to assess cylinder condition, when resealing is appropriate, and how Melbourne businesses can make informed maintenance decisions that protect both machinery and budgets.
When a Cylinder Starts Failing
Common symptoms of hydraulic cylinder wear include:
Oil weeping from rod seals or end caps
Unstable movement, such as “bouncing” under load
Loss of pressure when lifting or extending
Loss of pressure when lifting or extending
Unusual rod wear or visible scoring
Internal bypassing, leading to sluggish operation
These issues often stem from seal degradation, not mechanical damage. In over 70% of cases, the cylinder structure is still sound.
What Happens During a Reseal?
A professional cylinder reseal involves:
Disassembly of the cylinder and full internal inspection
Removal of old seals, wipers, O-rings and back-ups
Cleaning of the rod, barrel, gland and piston surfaces
Installation of new OEM-grade seals
Reassembly and pressure testing to verify sealing integrity
ACE Hoses completes this process in our Campbellfield facility, servicing both standard and custom cylinders.
Resealing vs Replacing: Cost Comparison
Task Typical Cost (AUD) Reseal standard 3” cylinder $250–$400 Replace with new cylinder $800–$1,300 Equipment downtime (per day) $800–$2,000
Where the rod and bore are undamaged, resealing is almost always more economical.
When NOT to Reseal
Resealing is not appropriate when:
The rod is bent or visibly scored
There’s pitting or corrosion inside the barrel
Threads or ports are stripped or damaged
The cylinder is no longer available, and specs are unknown
Internal components are non-standard or modified
In these cases, full replacement or remanufacturing may be the only viable option.
Seal Material Selection: It Matters
Not all seals are created equal. The wrong material can fail prematurely under heat, pressure, or fluid incompatibility.
Nitrile (NBR): Best for standard hydraulic oil, -30°C to 100°C
Viton (FKM): Ideal for high-temp systems and synthetic oils
Polyurethane: Durable under abrasion and high-cycle use
At ACE Hoses, we match seal material to the system environment, ensuring long-lasting results.
Melbourne’s Reseal Specialists
With over 40 years of hands-on hydraulic experience, ACE Hoses provides rapid cylinder reseals using premium parts and testing equipment. We service cylinders from:
Excavators and loaders
Agricultural implements
Cranes and tilt trays
Industrial presses and machines
Pickup and return available for businesses in Campbellfield, Epping, Somerton, and greater Melbourne.
Choose Repair Wisely – Ask the Experts for an Assessment
Hydraulic cylinder resealing offers a reliable and cost-effective repair path—but only when the decision is made before critical damage occurs. With the right partner, reseals restore performance, reduce costs, and keep machinery online.
Contact ACE Hoses to schedule a cylinder reseal assessment today.
