Banjo Bolt leak...???

[Thomas C Potter]

i have a caliper with the banjo bolt that will not seal. I am at the comfortable limit of bolt torque.
Is there a hard urethane washer that works better??

Unique solutions??

[justbob]

I truly hate to even ask but let’s get it out of the way..

I’m assuming you are using both copper washers and they are new?

If so perhaps a hairline crack in the caliper body where the threads are or the end of the hose?
Wrong threads on the bolt?
A burr on the sealing side of the bolt?
A pit on the caliper surface?
Wrong thickness of washers?

That’s all I’ve got.


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[marauderrocks51]

comfortable torque ? always torque those . you may be amazed at the tight difference with the correct torque . otherwise refer to what justbob put out for you .

[Fastbob]

Copper works well, just install new copper washers. Should be available at your local Ford dealer or auto parts store.

[crownvic97]

The first time I removed a banjo bolt I didn’t realize those copper washers needed to be replaced...make sure you are using new ones!

[justbob]

Out of laziness in sourcing new I’ve reused many times without issues, mainly on the motorcycles, but sometimes on cars. But yes, they are intended to be used only once.

Like I said, I hate to ask. I just don’t know you or your skills so I figured start at step 1.


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[marauderrocks51]

i agree out of laziness i also re used copper ones . flip them over and again torque it . currious to see what this problem is

[Thomas C Potter]

Thnx all, i was up to 20 ft.lbs and with only some 5 threads of engagement, I did not want to go higher.

Got some aluminum/rubber sealing washers, problem solved. There are 2 styles out there. I was using new copper.

When using ‘rebuilt’ calipers, the rings are sometimes imperfect due to corrosion from previous life.

[fastblackmerc]

Thnx all, i was up to 20 ft.lbs and with only some 5 threads of engagement, I did not want to go higher.

Got some aluminum/rubber sealing washers, problem solved. There are 2 styles out there. I was using new copper.

When using ‘rebuilt’ calipers, the rings are sometimes imperfect due to corrosion from previous life.

Is the rubber brake fluid "safe"?

[marauderrocks51]

So now the leak is fixed and the correct torque according to ford factory manual is 50 newton meters / 37 foot lbs . brake line pressure is extreme . get a good torque wrench and torque it .those are rear spec . fronts are 55 NM / 41# page 203-03-6 manual . power assit braking pressure approx, 1400 lbs . this way you can rest easy when you throw out the anchor . LOL

[Thomas C Potter]

Yes, safe for brake system, that is what they were designed for.
Torque limit for the car I am working on is 22.