In most times, a hydraulic cylinder can be repaired by changing out pistons or seals inside the cylinder. However, on rare occasions, you may need to replace the entire cylinder itself. If that situation arises, you will need to know how to correctly remove the old hydraulic cylinder and install a new one. This easy-to-follow how-to guide will show you to do just that.

Step 1 – Prepare to Work

First, disconnect the negative battery cable from the terminal post on your battery.

Step 2 – Jack Up the Vehicle (if needed)

Jack up your vehicle and place it on jack stands, so that you can work with the hydraulic cylinders on your vehicle.

Step 3 – Remove the Hydraulic Hose

Depending on your equipment, the hoses may be held to the cylinder using clips or clamps. However, in most cases, you’ll be able to remove the clamps with a wrench or other tool. Remove the screw from the clamp that holds the clipper clamped in place and disconnect the hose.

Step 4 – Remove the Hydraulic Cylinder

Remove the pins/bolts that hold the hydraulic cylinder in place.

Step 5 – Drain Hydraulic Fluid

Place a plastic bucket or container underneath the cylinder and hoses to catch the hydraulic fluid that may drain out. Then, hold the cylinder upside down in order to drain the remaining fluid into the bucket or plastic container.

Step 6 – Clean the Cylinder Area

Take a rag or towel and wipe the area where the hydraulic cylinder was installed to remove any dirt or grime in the area.

Step 7 – Install New Hydraulic Cylinder

Use the pins/bolts that were used to hold the hydraulic cylinder in place when installing the new hydraulic cylinder. Be sure to apply a sufficient amount of torque to the bolts to ensure that they won’t be loose when the vehicle is being operated.

Step 8 – Re-connect Hydraulic Hose

Connect the hydraulic hoses to the cylinder. Then, push the clamp or clip up to the end of the hose so that it can hold the hose in place. Tighten the bolts that lock the clamp or clip.

Step 9 – Fill with Hydraulic Oil

Locate the port on the master hydraulic cylinder and remove it or the cover. Fill the master cylinder with hydraulic oil and connect the hose. Then extend the cylinder using hydraulic system and fill the other side of the cylinder with hydraulic oil (for double-acting hydraulic applications).

Step 10 – Lower the Equipment

Remove the jack stands (if any) and lower the machinery.