Leaking Banjo Fittings / Banjo Torque Specs.

[CDXXVII]

I have been dealing with several leaks at my front brake calipers. (Both banjo fittings and one bleeder) These are 13" PBR dual piston aluminum bodied calipers. My MK4 Roadster manual shows the aluminum PBR calipers for the front as well.

Here are the torque specs from the manual.

Banjo bolt torque specs
Front Brake hose to caliper Banjo bolt – (39Nm) 29lbft
Rear brake caliper hose to caliper Banjo bolt – (43Nm) 32lbft

My rear calipers are steel so I can see the higher torque as being correct but 29lbft for the fronts seem high. Can you confirm these numbers?

My leaks are all gone for now but I was only comfortable taking the front banjo bolts to 20lbft. I replaced both bleeder screws because neither one would seat properly. I also replaced the aluminum crush washers with copper crush washers. Problems resolved except for the torque issue.

Please help for peace of mind

[jelag]

I agree the change from aluminum to copper crush washers... I'd not be afraid of the torque specifications if the length of the bolt... in other words the amount of the thread interface is at least 2X's the diameter of the bolt... 3/8" bolt 3/4" thread interface... anything less than that and I think I'd be more comfortable with a lower setting...

Also understand that the banjo bolt and crush washer are both harder metals than the housing... make sure there is no damage where the washer has to seal to the caliper..

Hope this helps.... good luck