Here we go:

I've got an entirely new disc brake conversion put into my 70 Chevelle. The problem I'm having is with the banjo bolt sealing to the caliper. I am using copper washers and Russell braided stainless hoses. One side seals up okay, but the pass. side drips just a little when I hit the pedal. graemlins/angry.gif It appears to be coming from the bottom of the hose/bolt on the caliper side.

The Russell hoses came with aluminum washers. From past experiences I have had better luck with the copper ones so I used those. Should I try the aluminum ones (if I can find them graemlins/clonk.gif )? Someone suggested Permatex but I would think that with the pressure of a brake system that would get pushed out? Any ideas would be greatly appreciated!!

THANKS!

Your instinct about Permatex is correct. Don't use it, because it won't seal. I'd pull the banjo fitting and inspect the mating surfaces of the fitting and the caliper very closely. When I've had this problem in the past, it was usually due to to a nick or burr in the area where the washer seats.

Also, check the washers to make sure they aren't cracked.

you might want to check the way you installed your banjobolt to caliper,beleive it or not there is a right and wrong way the pointed end i beleive should face up ,,just check your drivers side since its not leaking and make sure they are installed in the same direction,,i learned this doing mine last week put disc conversion on and it came with specific instructions on your topic,,,good luck....hope this helps...

You should be able to get the copper washers from Autozone or other autoparts store. I got mine from AZone. I have used both and think that the aluminum ones seem to work better due to being thicker and so there is more to crush and create a good seal. :D

I was unclear from your post: did you use the old copper washers or new ones? If the mating surfaces are good, make sure you use new washers whether you use copper or aluminum and that should clear up your problems.

Originally posted by Rich-L79:
I was unclear from your post: did you use the old copper washers or new ones? If the mating surfaces are good, make sure you use new washers whether you use copper or aluminum and that should clear up your problems. I used new copper washers. I ordered some new aluminum washers (can't find the original ones). I am going to see if that works. Thanks!!!

does anyone know the torque spec on the banjo bolts?

ALSO, i was thinking about this, there are bolts that are longer for 69 camaro and there are bolts .2" shorter for chevelle and 78 camaro. just maybe you bolt is bottoming out befor the washer is even being pinched? just a thought. smile.gif

I think Randy has the correct fix. Look at your caliper very closely. It can have a nick or burr or some rust if it is a rebuilt caliper, keeping your washer from sealing.