Treated the truck to new front pads today. The one caliper was kind of sticky so I put 2 re-man calipers on as well. Got it all bled out and went for a test drive and it all works well. I swear I can feel less rolling resistance. Got back and checked things over and noticed fluid weeping from the one banjo bolt. Checked the other one and same thing. In 30 years of doing this I've never had this issue. I tightened them a little more but I just can't get the copper washers to seal. I'm considering putting the old ones back on. I'm confident everything was clean when it went back together. Anyone ever have this problem and have any ideas? I hope this won't be like getting injector lines to seal. 

I wash able to get right brake washers at Napa but if you want to save money  and if washers are concave  turn them over.  Bring in old one with you.

Maybe the 02 is different, all my fittings are flare fittings, no washer involved.

I'm jealous of your fittings. Googleing it it appears this is a fairly common problem for some. I've just never had it. I'll try turning the washers and get some new ones as well. This stuff only happens when I need the truck

Clean the "circular etching/raised area" on the caliper and flip the washer, make sure the washer is clean. I had that problem earlier this year.

13 hours ago, dripley said:

Maybe the 02 is different, all my fittings are flare fittings, no washer involved.

 

They are? I have never seen a flare fitting used on the front calipers of these.

 

@dave110 take a hammer and smack the banjo bolt. Snug again with wrench or socket.

Edited October 27, 20177 yr by jlbayes

It's interesting you mention that @jlbayes. Mulling over it while trying to sleep I thought the same thing. One good whack with a brass hammer might seat the copper washers. It's the last thing I considered trying before taking it apart again. I wasn't  sure it was a good idea, so I'm glad you suggested as well. I broke a banjo once before so I'm a little gun shy. I'm gonna go at it again shortly and I'll report back.

44 minutes ago, jlbayes said:

 

They are? I have never seen a flare fitting used on the front calipers of these.

 

@dave110 take a hammer and smack the banjo bolt. Snug again with wrench or socket.

You are right. Had to think about that for a while and mine does have washers. I stand corrected.

Dang! I was all ready to do an 02 caliper conversion . Off to the shop to bathe in DOT 3 again.

Problem solved! I had those bolts about as tight as I could get them with 3 fingers on a 7/16 box wrench. After a few taps with a brass hammer I was surprised to get another 1/4 turn out of them. I suppose either the China bolt heads are not square to the threads or the crush washers are not parallel  or too hard or something, but the tap trick worked.

Now if only all my problems could be solved with a hit from a hammer...................

good to know 

On 10/27/2017 at 9:52 AM, dripley said:

You are right. Had to think about that for a while and mine does have washers. I stand corrected.

 

Got my hopes up there for a min as well LOL

Dave,

 

The copper was too hard.  Happens a lot with steam systems.  ( the copper should be dead soft and pure, but copper is expensive so they add tin, aluminum, zinc.... and they don't anneal it after the work hardening....) 

 

You can soften the copper/bronze washers.   heat them with a propane torch carefully until red.  drop them in cold water.  this will soften them.  (yes it sounds odd (it is opposite carbon steel), but I can go into why if you want...)

 

HTH

 

Hag