Another Leaking Banjo Bolt

[lkt1954]

Installed a disc brake conversion kit from POL and I'm in the process of trying to bleed the brakes.
The only thing stopping me is the leaking banjo bolt on the drivers front caliper. I've tried 3 different sets of copper washers and not solved the problem. Every time, I tightened the banjo bolt as tight as I could with a breaker bar, still leaks.

In looking at the caliper, I have come to the conclusion it's a casting issue with the grooves where the washer goes. On the top right side the ring is almost smooth. I'm sending this picture to POL to see what they say.
Does this look like a casting issue anyone or is it just crappy copper washers?

Any thoughts, suggestions or ideas?

Thanks

[raggedjim]

Just a thought, some of the copper washers I have seen lately seem too "hard" to me compared to the original ones. They are supposed to be soft annealed. Just looking at the caliper I feel like it should seal.

Good luck, Rg

[lkt1954]

I thought about that as well.
Who can you get good copper washers from??
Tried what came with the conversion kit and ones from O'Reilly's and AutoZone.

[Killer Bee]

could be;

• weak grooves (although many fittings are smooth)
• caliper fitting land is not flat
• overtightening and distortion - breaker bar not required
• surrounding cast interference with fitting orientation
• combination of issues

as for copper washers, I've used dozens of brands and 'close' sizes without issue

good read on the subject - good luck!

Common Causes for Leaky Banjo Fittings and Caliper Issues

[LS short box]

It's a bit out there but maybe take the new washers and wet sand them on both sides. 400 wet sand paper? laying flat on something like a piece of glass so it's super flat.

Times 10 on not using a breaker bar. If you strip the threads your warranty to send back will be toast.

[Getter-Done]

Great advice above.
I will add one thing.

Use a (Wet Rock) sharpening stone to remove high spots or check for flatness of the Banjo block.

You can clean the residue with brake cleaner once it is verified flat on both sides.

Link: https://www.harborfreight.com/combin...one-62852.html

[lkt1954]

Thanks for all the information.
I had read that article in Speedway and my order the washers he is talking about.
As to the breaker bar, just using a 3/8" socket sized bar and not going crazy tightening it and the bolt is not stripped out.
I'll try sanding some new washers to see if that helps.

Thanks again