leaking at banjo bolts - FFCars.com : Factory Five Racing Discussion Forum

Missouri Rodder · 08-20-2012, 08:02 PM

have FFR hot rod. using FFR kit front brakes. Wouldn't you know it, i painted the calipers all up to match the back (Black) and using Dot 4 fluid. Long story short, i can't get the banjo bolts to stop leaking fluid. I have put way too much pressure on them to tighten them down. I have went and bought some copper washers, still leaking. I have now coated some washers with liquid teflon and am considering taking them back apart to install these. Just wondering if someone else has had the issue. I do see some machine markings on the caliper housings but turning them is probably my next trial. I have just never had this much issue with brake line leaks. appreciate to hear from anyone else with this issue. ser number is like 10k327. just got the kit in Feb 2012. at the point of installing motor/transmission.
thanks, Todd.

Rich A · 08-20-2012, 08:24 PM

Did you torque the new washers and banjo bolt to 30ftlbs?

Missouri Rodder · 08-22-2012, 10:18 AM

you bet, i'd say more like 80-100 ft lbs, still leaking. I looked a machine surfaces of calipers, really visually look decent, not perfect but decent. Maybe banjo bolts too long but lies are not loose either.

1fastsedan · 08-22-2012, 01:18 PM

You can try installing the bolt without the washers to check if its too long or not. If it bottoms out without the washers on, I'd grind an 1/8th to 1/4" off of the bottom of the bolt, provided that doesn't get near the hole.

bmcglone · 08-23-2012, 02:27 AM

Replace the banjo bolts. I had the same problem on a MK4 Roadster. After three sets of washers I replaced the banjo bolts and the leak stopped.

rich grsc · 08-23-2012, 09:27 PM

I agree, sounds like the wrong bolts.

joseph chiappetta · 10-04-2012, 04:59 PM

This is a late respopnse but just for info I had the same issues with one of the Banjo bolts on a Master Cylinder and also on 2 of the SS Brake hoses. New copper washers and/or more torque did not solve the problem. The problem was rough surfaces on the faces of the fittings. I polished the surfaces with a very fine knife sharpening stone and the problem was solved.

ram_g · 10-04-2012, 06:06 PM

Had the same problem with mine (back in 2008/09) - could not fix with new copper washers and/or torque. Someone suggested Earl's Stat-o-seals and sure enough that did the trick.

See here for example:
http://www.summitracing.com/parts/EAR-178009ERL/