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Old 04-07-2013, 02:52 PM   #1
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Banjo Bolt Leaking with new washers

I am installing extended brake lines on my TJ today and the first one I tried leaks from the banjo bolt with the new washers installed. After that attempt, I tried using the second set of new washers with the same result. The washer at the bolt side is crushing but the one between the hose and caliper doesn't look like it is compressing hardly at all. I need to run up to the parts store to get more washers to try again but wanted to know if anyone else out there has had this problem. The lines I'm using are Crown Automotives.

Custom Extended 5-Layer Stainless Brake Lines for Wrangler TJ & Unlimited by Crown Industrial

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Old 04-07-2013, 02:55 PM   #2
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I had the exact same issue. What's happening is the edge of the nut on the brake hose is sitting against the caliper putting pressure on the banjo bolt. You need to put the flat side of the nut facing the caliper.

Probably hard to imagine with the description, but see if the nut on the brake line is rubbing on the caliper.

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Old 04-07-2013, 03:20 PM   #3
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Quote:
Originally Posted by Moabrubi View Post
I had the exact same issue. What's happening is the edge of the nut on the brake hose is sitting against the caliper putting pressure on the banjo bolt. You need to put the flat side of the nut facing the caliper.

Probably hard to imagine with the description, but see if the nut on the brake line is rubbing on the caliper.
Thanks Moab. I haven't had a chance to go to the parts store since I'm stuck at home with a 5 year old and a napping 2 year old. I ran out and took it apart again to take a closer look at the washers. The one between the caliper and hose is getting pocketed in a shallow groove on bot the caliper and the hose itself. Even without wrenching down, the hose sits flat agains the caliper. I think I need thicker washers than what came with the kit.

The bolt-head side is on the left and caliper-side on the right.
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Old 04-07-2013, 06:21 PM   #4
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Got it done. The washers were too thin. Advanced Auto only had assortment packs with the thicker washers so I had to buy two packs of them to get it done. My wife was stellar in helping me bleed my brakes. Not bad for a blonde. Of course she did complain about how dirty the inside was. I got my laugh in watching her try to get up into the Jeep. She hasn't been in it since I had a 2" lift.

Anyway, the gap you see here wasn't there with the washers that came with the kit. The counter guy asked me if I tried teflon tape. He says he had to do that on his F150 and it's been fine. Now I'm going to be paranoid everytime I see one in my rear view.
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Old 04-07-2013, 10:38 PM   #5
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Got it done. The washers were too thin. Advanced Auto only had assortment packs with the thicker washers so I had to buy two packs of them to get it done. My wife was stellar in helping me bleed my brakes. Not bad for a blonde. Of course she did complain about how dirty the inside was. I got my laugh in watching her try to get up into the Jeep. She hasn't been in it since I had a 2" lift.

Anyway, the gap you see here wasn't there with the washers that came with the kit. The counter guy asked me if I tried teflon tape. He says he had to do that on his F150 and it's been fine. Now I'm going to be paranoid everytime I see one in my rear view.

In a pinch and only if it was necessary, you could stack two of the thinner versions next to the caliper as a trail fix or to get you to the parts store and back.

It will work, but it deeply offends my sense of correctness although not as bad as Teflow tape does.
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Old 04-07-2013, 10:55 PM   #6
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In a pinch and only if it was necessary, you could stack two of the thinner versions next to the caliper as a trail fix or to get you to the parts store and back.

It will work, but it deeply offends my sense of correctness although not as bad as Teflow tape does.
I considered stacking just to stop the leaking if the ones I got from AA didn't work. At least until I could find a supplier with thicker washers. It's not my daily driver and I wouldn't drive it like that. You should have seen my face when he mentioned teflon tape.
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Old 04-07-2013, 11:20 PM   #7
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I considered stacking just to stop the leaking if the ones I got from AA didn't work. At least until I could find a supplier with thicker washers. It's not my daily driver and I wouldn't drive it like that. You should have seen my face when he mentioned teflon tape.
It probably resembled my face when a well known and respected Jeep specific shop told me that locking up the front brakes on a TJ was such a bad idea that if they had one that got anywhere near being able to do so that they installed an adjustable proportioning valve on the front circuit to dial that out.

I wanted to do this with both hands full of bricks to him.
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Old 04-08-2013, 12:09 AM   #8
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Ahh much different issue then my Goodridge lines. My washers were fine the actual connection to the banjo bolt was hitting the caliper.

Also my kit came with an extended line for the rear. I really don't see the purpose for it as my axle was damn near touching the floor and the stock line was still fine.
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Old 04-08-2013, 12:18 AM   #9
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The Crowns came with the rear. Maybe one day if I'm bored I'll put that on. I don't see it as a necessity.

Quote:
Originally Posted by Black Magic Brakes View Post
It probably resembled my face when a well known and respected Jeep specific shop told me that locking up the front brakes on a TJ was such a bad idea that if they had one that got anywhere near being able to do so that they installed an adjustable proportioning valve on the front circuit to dial that out.

I wanted to do this with both hands full of bricks to him.
If you have to lock them up, you have to lock them up. I wouldn't mind ABS though.

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