Malabar 45-Ton Axle Jack – 8842

Follow these steps to change out the seal kit on the hand pump for the Malabar 8842 Axle Jack:

1. Remove the pins and fulcrum mounts.
2. Place the unit in a vise using rubber pads to prevent damage to surface areas.
3. Remove the pistons.
4. Clean out all surface areas. Remove gaskets and steel balls.
5. On the bottom of the pump, remove both pump return screws and the gaskets.
6. Remove the spring and stainless steel ball inside of each port.
7. Inspect all steel ball seating areas on both the top and bottom of the pump for any defects.
8. Reinstall the bottom plugs with new seals.
9. Insert new steel balls. Install new springs. Replace the plugs.
10. Install the first backup ring into the groove of the piston chamber. Ensure the seating is as flush as possible.
11. Install the new O-ring on top of the backup ring.
12. Install the second backup ring on top of the O-ring.
13. Install the new wiper ring.
14. Repeat the above process (steps 10-13) for the high-pressure pump.
15. Lube the pistons and slide them into place for both units. Be sure not to damage or remove the backup rings.
16. Prepare the threads for reinstallation into the pump block. Make sure the threads are clean. Seal the threads with Loctite 567.
17. Thread it down until it’s hand-tight. Secure with a wrench.
18. Repeat the process (steps 15-17) for the high-pressure pump.
19. Reinstall the fulcrums and pins for both units.
20. Remove the three seals and replace them with new ones.
21. Using a flat-head screwdriver, remove the screens in the jack and install new screens. The screens must sit inside the pump face. Otherwise, they will make contact with the jack, and it won’t seal properly.
22. Beginning with the top bolt, thread into the face of the block to hold the pump in place. Make sure all bolts are tight to ensure a good seal.

To keep your Malabar 8842 axle jack operating reliably, it’s a good idea to maintain a small inventory of commonly replaced components. These spares help minimize downtime and ensure fast servicing when wear items need attention. Recommended parts include:

• 8842PK – Repair Parts Kit
• 492-012 – Swivel Caster
• 492-002 – Wheel
• 86339 – Breather Cap & Dipstick
• 884212 – Hydraulic Hose
• 86387 – Air Pump*
• 441-022 – Air Pump Seal Kit*
• 884225 – Load Gauge*
• 471-002 – Lubricator*

*Only required if your jack was originally supplied with these pneumatic components.

Yes. When servicing the Malabar 8842 aircraft axle jack, two specialty tools are required to properly disassemble and reassemble the cylinder assembly. These OEM-specified tools ensure safe handling, correct torque application, and protection of the jack’s internal components. Both tools are available for purchase through PJi:

• 884255 – Ring Stop Spanner Wrench
• 83224 – Extension Screw Lifting Tool

The Air Retract (AR) option is designed to speed up the plunger retraction process on the Malabar 8842 aircraft axle jack, allowing the jack to return to its lowered position quickly and with minimal manual effort. This pneumatic assist is especially useful during frequent or time-sensitive maintenance operations, where faster cycling of the jack improves workflow efficiency. By reducing reliance on manual retraction, the AR option also helps lower technician fatigue and supports smoother, more consistent shop or ramp operations.

Yes. The Malabar 8842 aircraft axle jack is CE-marked and conforms to all applicable EU machinery and safety directives. This certification ensures the jack meets European regulatory requirements and can be sold and operated throughout the European Economic Area (EEA). For operators working internationally, the CE mark provides added assurance of compliance and equipment quality.