Brake banjo bolts.................

[jusjunk]

got one bolt that wont seal . Tried working the copper washer over a little and it still wont seal. the sealing area looks good.. Anyone got an idea. I hate to tighten it any more its pretty tight now..
Dave

[Bruce Dorsi]

Dave, any chance the threaded portion is bottoming out before the seal washers are compressed enough?  

I've seen some banjo fittings on hose ends with oversize holes.  (Wrong hose?)  ...These make it interesting when trying to make a good seal.

[jusjunk]

Ill check that but dont think its bottoming out. Got the right ends bolts and washers. One side seals good the other dont. Ill probably stop tomorrow and buy some new copper washers but the ones i used were new. I cant find the ones i had from speedway and i think they were aluminum. Id try em if i could find em..

[enjenjo]

Check to see if the bolt is bottoming out. I have had that problem in the past. The parts store here has some thicker copper washers that fixed it up.

[mrloboy]

Install the banjo bolt in the caliper without the hose and snug it up. Measure the space between the head of the bolt and the sealing surface on the caliper. Check the measurement against the hose end, including the copper washers to determine if the bolt will allow adequate crush on the washers to obtain a proper seal. If not, the threaded ends of the Banjo Bolt will need to be machined off or thicker crush washers will need to be used.  rj

[Ed ke6bnl]

Install the banjo bolt in the caliper without the hose and snug it up. Measure the space between the head of the bolt and the sealing surface on the caliper. Check the measurement against the hose end, including the copper washers to determine if the bolt will allow adequate crush on the washers to obtain a proper seal. If not, the threaded ends of the Banjo Bolt will need to be machined off or thicker crush washers will need to be used.  rj

Might try heating the copper washers till red that will aneal can cool fast it water if you like  and they may seal while soft.  If the measuring suggestion checks out. Ed ke6bnl

[flt-blk]

You are using one washer on top and one on bottom, right??
TZ

[SKR8PN]

If the bolt is bottoming out,before the washer seal,I have noticed that some copper washers are a little bit thicker than others,to prevent that from happening. Might want to look into that...

[jusjunk]

Heres what I did.. Stopped and bought new copper washers. Took the old washer for the bottom that leaked and heated it cherry red and let it cool. Cleaned it with a scotch brite pad put it back together cranked it down got my trusty piece of aluminum round stock about 3 inches long and a hammer. BAAAAAAAAAAAAAAAAAAM Hit that sob and cranked it some more> then BAAAAAAAAAAAAAAM one more time , cranked it down again. Doesnt look like it leaks now. I think its seated and sealed....
Dave
ps: I really didnt hit the bolt that hard ,just enuff to seat the washer

[enjenjo]

Ahhhh..........Percussion machining, works every time.