I asked that it be marked solved (blame drbits).
It is a Won't fix. It is rare enough and easy enough to work around that there is no reason to make JDownloader more complex to support this case. Expansion is a "nice to have", but not part of the core purpose of JDownloader (downloading a list of links). As you know, the JD team is already understaffed.
JDownloader is only supposed to expand when all of the parts are in the package. In the future, it might check for that and refuse your request to expand.
In fact, it is a surprise that it worked at all. This is a case of the person who supports unrar.exe adding what should be unnecessary code.
If you need to manually expand, you can use 7zip (or IzArc or WinRAR).
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