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Leaking brake line at the banjo bolt. GRRRRR!

Posted By: cudadoug

Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:05 AM

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.

Attached picture 8445658-caliper.pic.jpg
Posted By: convx4

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:12 AM

Try dubbing up the copper washers on that side.

Doing this cured the same leak I had.
Posted By: moparpollack

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:20 AM

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.
Posted By: 71birdJ68

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:22 AM

Is that a pin, or slider caliper?
Posted By: cudadoug

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:23 AM

Dubbing?? You mean like Dubbing wax?
Posted By: moparpollack

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:24 AM

Quote:

Dubbing?? You mean like Dubbing wax?



Doubling them up.
Posted By: Supercuda

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:26 AM

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.
Posted By: cudadoug

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:27 AM

Oh...DUBB-LING them up. I get it.

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

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:28 AM

Quote:

Is that a pin, or slider caliper?



Slider.
Posted By: cudadoug

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:29 AM

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!
Posted By: YO7_A66

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:41 AM

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.
Posted By: therocks

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 03:48 AM

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
Posted By: AndyF

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 04:08 AM

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.
Posted By: cudadoug

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/02/15 04:43 AM

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!
Posted By: BDW

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/03/15 01:10 AM




As mentioned, look through the help packs.



Posted By: cudadoug

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/30/15 07:33 AM

HELP #66272 solved the problem. Results: Hard pedal and a dry garage floor!

Thank you guys!!!
Posted By: bordin34

Re: Leaking brake line at the banjo bolt. GRRRRR! - 03/30/15 04:18 PM

One thing you can also do easily is anneal the copper washers to make them softer and seal better.
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