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Leaking brake line at the banjo bolt. GRRRRR! #1768713
03/01/15 11:05 PM
03/01/15 11:05 PM
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Between a rock & a hard place
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cudadoug Offline OP
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cudadoug  Offline OP
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Installing a Disc conversion kit and have a minor headache.

Can you see the flaw in the serrations in this pic?? At 9:00, two of serrated edges have flat spots, like it was nicked in production or shipping.

You think this cause a leak with THREE different sets of crush washers?? First two attemps, torque was 25 ft lbs. Third attempt I tried 30 ft lbs. Drip, drip, drip.

It's the only thing I can see that's wrong, the other side sealed up first time.

8445658-caliper.pic.jpg (294 downloads)
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768714
03/01/15 11:12 PM
03/01/15 11:12 PM
Joined: Feb 2005
Posts: 709
St Louis, MO 63026
convx4 Offline
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Try dubbing up the copper washers on that side.

Doing this cured the same leak I had.

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: convx4] #1768715
03/01/15 11:20 PM
03/01/15 11:20 PM
Joined: Nov 2005
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85086
moparpollack Offline
Lil Herman
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Quote:

Try dubbing up the copper washers on that side.

Doing this cured the same leak I had.




The shim washers are so thin I have never got them to seal any other way.


56 Plaza 63 D100 step side 67 Coronet, 68 Roadrunner, 69 Super Bees, 69 Coronet 500 convertible, 70 Roadrunner Post, 79 D150 360, and a severe case of Mopar a,d,d
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768716
03/01/15 11:22 PM
03/01/15 11:22 PM
Joined: Feb 2012
Posts: 4,454
Morristown Tn.
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71birdJ68 Offline
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Is that a pin, or slider caliper?

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: moparpollack] #1768717
03/01/15 11:23 PM
03/01/15 11:23 PM
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Between a rock & a hard place
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cudadoug Offline OP
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Dubbing?? You mean like Dubbing wax?

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768718
03/01/15 11:24 PM
03/01/15 11:24 PM
Joined: Nov 2005
Posts: 15,119
85086
moparpollack Offline
Lil Herman
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Quote:

Dubbing?? You mean like Dubbing wax?




Doubling them up.


56 Plaza 63 D100 step side 67 Coronet, 68 Roadrunner, 69 Super Bees, 69 Coronet 500 convertible, 70 Roadrunner Post, 79 D150 360, and a severe case of Mopar a,d,d
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: moparpollack] #1768719
03/01/15 11:26 PM
03/01/15 11:26 PM
Joined: Sep 2007
Posts: 14,889
up yours
Supercuda Offline
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Ran into this years ago with reman calipers. Ended up going to Pep Boys and looking thru their copper washer selection till I found thicker ones of the right diameters cause the supplied ones were too thin. What's happening is the bolt is bottoming out before the washer seals.


They say there are no such thing as a stupid question.
They say there is always the exception that proves the rule.
Don't be the exception.
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: moparpollack] #1768720
03/01/15 11:27 PM
03/01/15 11:27 PM
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cudadoug Offline OP
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Oh...DUBB-LING them up. I get it.

I'll give it a whirl, thanks. BACK to the auto parts store...

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: 71birdJ68] #1768721
03/01/15 11:28 PM
03/01/15 11:28 PM
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cudadoug Offline OP
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Quote:

Is that a pin, or slider caliper?




Slider.

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: Supercuda] #1768722
03/01/15 11:29 PM
03/01/15 11:29 PM
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cudadoug Offline OP
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Quote:

Ran into this years ago with reman calipers. Ended up going to Pep Boys and looking thru their copper washer selection till I found thicker ones of the right diameters cause the supplied ones were too thin. What's happening is the bolt is bottoming out before the washer seals.




Yes, these are thin!

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: Supercuda] #1768723
03/01/15 11:41 PM
03/01/15 11:41 PM
Joined: Jan 2003
Posts: 5,444
Indiana
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YO7_A66 Offline
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Indiana
I too had this problem but my kit had two different washers of different thickness. I could not get the thin one to seal so I tried the thicker washer and it sealed.


1970 YO7 A66 [Canadian Export] F8 Challenger
340 (Currently in shop for stroker assy.)
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: YO7_A66] #1768724
03/01/15 11:48 PM
03/01/15 11:48 PM
Joined: Jan 2003
Posts: 21,074
Niles , Ohio
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therocks Offline
oh wait.but hey.lets see.oh yeah.
therocks  Offline
oh wait.but hey.lets see.oh yeah.
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Niles , Ohio
Most of the new washers are crap.I almost always used the old ones to seal.Seems the new ones almost always leaked.Ive use ones that were worse than that and no leaks.Rocky


Chrysler Firepower
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768725
03/02/15 12:08 AM
03/02/15 12:08 AM
Joined: Jan 2003
Posts: 31,048
Oregon
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AndyF Online content
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Oregon
Might have better luck if you buy OEM washers. Should still be available at the dealer. The OEM washers are thick and might be a softer grade of copper.

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: AndyF] #1768726
03/02/15 12:43 AM
03/02/15 12:43 AM
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Between a rock & a hard place
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cudadoug Offline OP
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Quote:

Might have better luck if you buy OEM washers. Should still be available at the dealer. The OEM washers are thick and might be a softer grade of copper.




Never thought of that, thank you Andy! I went to two REAL parts stores and what they have are thin AND a smaller diameter than the serrations are.

In hindsight, SHOULD have probably went with the Wilwoods!

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768727
03/02/15 09:10 PM
03/02/15 09:10 PM
Joined: May 2005
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Florida
BDW Offline
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As mentioned, look through the help packs.




Last edited by cnxt; 03/02/15 09:13 PM.
Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: BDW] #1768728
03/30/15 03:33 AM
03/30/15 03:33 AM
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Between a rock & a hard place
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cudadoug Offline OP
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HELP #66272 solved the problem. Results: Hard pedal and a dry garage floor!

Thank you guys!!!

Re: Leaking brake line at the banjo bolt. GRRRRR! [Re: cudadoug] #1768729
03/30/15 12:18 PM
03/30/15 12:18 PM
Joined: Oct 2006
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Urbana, MD
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bordin34 Offline
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Urbana, MD
One thing you can also do easily is anneal the copper washers to make them softer and seal better.







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