Ok on my 73 Charger driver's side front caliper. I initially replaced everything during my restore. Caliper, hose, washers, bolt, and brake lines. This line keeps leaking at the banjo bolt. It's hard to determine if it's leaking between the brass hose block and the caliper or the block and the bolt because it's too wet. I replaced the washers 4 different times and even tried the original Chrysler thick washers. I rechanged the banjo bolt. I even warrantied another caliper. I finally tried a new brake hose last night. It's still leaking just as bad. And this only just sitting in the garage. I haven't even driven it yet. The other side caliper is fine. Should there only be one washer on the banjo bolt? In the 73 parts catalog it states 4 required. But I don't know what else to try now.

are you using in this order caliber/copper washer/brake hose fitting/copper washer/bolt with hole. some of the after market washers do not work. make sure everything is seated level.

joe

You do know you need a washer on each side of the fitting, right?

You need the MP washers (4 total) that have the circular rings like a tree trunk and check that they are thick enough to be higher than the recess in the calipers and check for no burrs/debris on the contact surfaces on the hose fitting nor the caliper recess and that the washers slightly nestle into the matching circular grooves on the hose fitting.

Well I thought it was a pretty easy diagnosis. There's not much happening since there's no pressure being applied. It's leaking just sitting there. So since everything was under warranty I went ahead replaced the caliper. The hose I had on there didn't really match the original so it didn't cost me but $11 for the right one and then $4 each for the washers. So I'm not into it much but either way it's still leaking. I just took everything back off for about the 4th time. This time I took the hose off and check the flange on the caliper and it looked smooth an clean. I cleaned off the mating block of the hose and the washers. I used the original Chrysler washers this time and I torqued down the bolt to 25LBS-FT as stated by my 73 Chrysler service manual. So I did it all with the caliper off the car to make sure I wasn't misaligning the washer or the hose. So I can't really do it anymore precise. So I'll have remount it and see what happens. I'll have to totally rebleed the whole brake system again, it's pretty much lowered the fluid level in the master cylinder enough. It's a pain, there's no leaks anywhere else but this caliper. I don't have an original or NOS bolt I'm stuck with the Dorman replacement bolts from the parts stores. That's what I've got on it now, I've tried the flanged one too, but the same thing happened. Should I try and find an NOS bolt?

Make sure the bolt doesn`t have a hairline crack. Also, I once had a rebuilt caliper where the ring grooves on worn away so bad the washer wouldn`t seal.

If it doesn't work I guess I'll have to try another caliper. These are remanufactured calipers so I'm sure some of them have been in service a long time and may have more pits than other at the sealing surface. I didn't see anything when I removed it but I can't really tell. There's no source for an NOS or new floating caliper like this anymore. Even if you find NOS I don't think it's complete, it's just the housing.

by reading your post I have to believe the bolt is too long or wrong diameter or your sealing washers are too thin.

I have stacked washers before..people say not to but I haven't had any failures.

Take a look at this, you only need the thick 1 on the caliper side. The after market thin washer will usually work on the hose side. At $4 each Mopar is really sticking it to us.

I don't know if the problem is the bolt, washer, caliper, or hose? After I thought I fixed it for sure last night I got up this morning and of course it was still leaking, although not all over the floor. I can't do it anymore correct than the way I did yesterday. I used the NOS Mopar washers and torqued it with the good torque wrench I used when rebuilding the engine. I'm using the Motormite banjo bolt part #13938 which is listed for a 73 Charger. I'm sure it's not exactly like the original bolt but the threads are the same. I don't have an original to compare it to. It looks like it's leaking from under the bolt head, not the caliper to block mounting area.

Can the hose be moved once tight? As suggested the bolt may be too long and bottoming out. Put the bolt in without the hose and measure the gap. I would maybe look for some oem bolts.

Well I was going to buy some NOS banjo bolts part #6030026. One guy wanted $23 each + $3 shipping and the other guy wanted $20 + $11 shipping. That's without new washers. If they've had those bolts on the shelf for 37 years they'll probably still have them in another 37 years for $20+ a piece, that's not a box, it's just one bolt. I can get a used one from a 73 Charger hopefully this week. Today I pulled one from an 87 Chrysler Fifth Avenue because it had the same type caliper, but I don't know if it's going to work. I didn't even have to pay for it either. This 73 Charger I have looks like it's going to be one of those that leaks everything. I had a transmission that was leaking in several places but think I got it fixed finally. Now it looks like the rear pinion seal is dripping even after it was replaced. Luckily haven't had any oil leaks on the rebuilt motor. I've never had so much trouble out of a brake line.

Try this:
Use the original Chrysler washers, but before you install them heat them up red hot with a propane torch and then immediately drop them in cold water. Copper work hardens easily and this will soften them up a bit.

try swaping bolt with other side and see if it leaks, then try swaping washers, hose ect, till you see which part is causing the leak, narrow it down to find the problem. good luck

I didn't want to take the other side off and possibly have the same problem again. I did clean up the original banjo bolt I pulled from a 87 Chrysler Fifth Avenue which according to Chrysler still uses the same part #6030026. I put it on using the Chrysler thick washers, but it still leaked. So I tightened it up some more. The factory torque for the bolt is 25LBS-FT, I tried that and it leaked. It's definitely leaking from the gasket to bolt head area. But why, I changed it over and over. I don't have anything else to try. The washers seem to me more rounded on one side and totally flat on the other. Does it matter which way you place the washers? Some have said to double up the washers. Should I double up the thicker Chrysler washers or the cheap Taiwan washers?

flat sided to hose, are you sure you have the right size gaskets?

Tighten the bolt more.. I've had plenty through the years that seeped, never broken a banjo bolt.. The copper washer needs to conform top any irregularities in the surface it is sealing, they don't conform easily... If your worried about the bolt being over stressed replace the bolt after using it to force the washers to conform to the caliper & hose surface.. But before you do test to be sure the leak is gone.. That way when the new bolt leaks you'll feel OK about torquing the new bolt...

I had to tighten mine much more than 25lbs. Didn't use a torque wrench, but I would bet it's closer to 50.