Actuators are the workhorses of automation. Whether they’re powering machinery on a factory floor, adjusting a hospital bed, or moving a hidden TV lift in someone’s home, they keep things running smoothly. But like all equipment, actuators don’t last forever. When one fails, you’re suddenly stuck with a big decision: should you fix it, or replace it altogether?
Let’s break down why actuators fail, when repair makes sense, and when it’s smarter to replace.
Why Actuators Stop Working
Actuators are built to last, but daily wear, harsh environments, and even misuse can take their toll. The most common culprits include:
- Electrical problems – Issues like bad wiring, burnt-out motors, or faulty control boxes can stop movement.
- Mechanical wear and tear – Over time, gears, bearings, and lead screws degrade, especially under heavy loads.
- Environmental factors – Dust, moisture, or corrosion can sneak in and wreak havoc, particularly outdoors.
- Overloading or misuse – Exceeding duty cycles, stroke limits, or force ratings leads to premature failure.
Is It Worth Fixing?
Not every breakdown means it’s time to buy new. If the issue is small, a repair may be all you need — but only if the actuator is designed to be serviced. Many sealed electric actuators aren’t built for user repair, and opening them could void warranties.
Repair is usually worth considering when:
- The problem is minor, like a loose wire, a limit switch adjustment, or insufficient lubrication.
- Spare parts (such as gears, motors, or bearings) are available and easy to swap.
- Repair costs are much lower than replacement.
- You can tolerate a bit of downtime while the repair is done.
- The actuator is specialized or custom-built, making off-the-shelf replacement difficult.
In short: if it’s fixable, cost-effective, and doesn’t disrupt your operations too much, repair is a smart choice. Check the blogs dedicated to our PA-14 and PA-15 electric linear actuator repair to learn how to fix and replace actuator parts.
Knowing When to Replace
Sometimes, repairing just doesn’t make sense — especially if reliability is critical. Replacement is usually the better option when:
- The actuator has major damage (bent shafts, stripped gears, or a burnt-out motor).
- The model is discontinued and spare parts no longer exist.
- Failures keep happening, even after multiple repairs.
- Downtime is expensive, and swapping in a new unit is faster than waiting on a fix.
- You’re ready for a technology upgrade — newer actuators may be quieter, more efficient, or more durable.
If your actuator is eating up time and money with constant issues, replacement often pays off in the long run.
Explore our collection of electric linear actuators, from micro to industrial capabilities!
Before You Decide: What to Think About
The right choice depends on more than just what’s broken. Ask yourself:
- Cost: Will a repair really save money, or is a new unit more economical long-term?
- Downtime: Can your system afford to wait for a fix, or must it be running immediately? (e.g., hospital beds vs. home furniture).
- Longevity: How much extra life will the repair add compared to buying new?
- Warranty: New actuators typically include coverage; repaired ones usually don’t. Some manufacturers only offer replacement, not repair, under warranty.
- Criticality: If the actuator is part of a safety system or mission-critical equipment, reliability must come first.
Steps to Extend Actuator Life
Whether you decide to repair or replace, prevention is the key to longer actuator life. A little care goes a long way:
- Do routine maintenance — clean, lubricate, and check for wear.
- Stay within ratings — don’t overload or exceed duty cycles.
- Protect from the environment — use seals, covers, or enclosures to guard against dust, water, and corrosion.
- Monitor performance — unusual noise, slower speeds, or excess heat are early warning signs.
- Choose the right actuator upfront — matching specs to the job reduces the chance of premature failure.
FAQ
What are the signs that an actuator needs repair?
If your actuator is making unusual noises, moving slower than normal, running hot, or showing jerky and inconsistent motion, these are early signs that it may need repair. In some cases, it may stop moving entirely due to simple issues like loose wiring or lack of lubrication.
How do I know if it’s better to replace my actuator instead of fixing it?
It’s usually better to replace an actuator if it has major damage, repeated failures, or if parts are no longer available. Replacement also makes sense when downtime is costly or when you want to upgrade to a newer, more efficient model.
Can I repair an actuator myself, or should I contact support?
Simple issues such as loose wires, limit switch adjustments, or lubrication can often be done yourself. For more complex problems like gearbox or motor damage—especially with sealed actuators—it’s best to contact the manufacturer or technical support.
How much does it typically cost to repair vs. replace an actuator?
Repair is usually more affordable if it involves minor fixes or readily available spare parts, but costs add up if the actuator keeps failing. In many cases, replacing a heavily damaged or obsolete actuator is more economical over time.
What steps can I take to extend the life of my actuator and prevent failure?
Regular cleaning, lubrication, and inspection go a long way in extending actuator life. Staying within load ratings, protecting it from dust and moisture, and watching for early warning signs of trouble help prevent breakdowns.
A Final Word
So, repair or replace? The answer depends on the problem, the costs, and how critical your system is. Small fixes are often worth it, but if your actuator is badly damaged, obsolete, or failing repeatedly, replacement is the smarter move.
Ultimately, making the right call ensures your system stays reliable, efficient, and future-ready. If you need professional help deciding whether to repair or replace your actuator, don’t hesitate to reach out to us.
At Progressive Automations, we’ve been a leader in linear motion technology for over 15 years, helping engineers, manufacturers, and DIY enthusiasts find the perfect motion solutions for their projects. By knowing your actuator’s limits, keeping up with maintenance, and upgrading when it makes sense, you’ll save time, money, and plenty of frustration down the road.