Snapping Rear Banjo Bolts

[cv2065]

Manual says 32 ft-lbs for the rear banjo bolts. No issues with the front ones, just the rear. Tried 30 ft-lbs and 'sneaking' up on it and still crack boom bam, still tore its head right off. Is there a different angle or something at the rear caliper that causes undue stress on the head of the bolt or something? Just find it weird that the fronts have no issue, just the ones in the back. Tested two different torque wrenches just to be sure they were correct.

Have some more banjo bolts on the way, so I guess I'll just get snug and then another 1/4 turn or so. If it leaks, I'll just tighten up a bit, but anyone else have the same issue?

[NAZ]

32 ft-lbs on banjo bolts? Not sure what you're using but Wilwood M10x1 banjo bolts on their calipers are torqued to 96-120 in-lbs and a note to torque to the lower value and check for leaks and to never exceed 144 in-lbs. 144 in-lbs is ~11.99 ft-lbs. Sure you're not looking at the caliper mounting bolt torque?

[BadAsp427]

32 ft-lbs on banjo bolts? Not sure what you're using but Wilwood M10x1 banjo bolts on their calipers are torqued to 96-120 in-lbs and a note to torque to the lower value and check for leaks and to never exceed 144 in-lbs. 144 in-lbs is ~11.99 ft-lbs. Sure you're not looking at the caliper mounting bolt torque?

Here is what I just found in the newest build manual sent to me by FF 2 months ago...
95595 95596

[cv2065]

What Carl just posted is straight out of the same manual I have. Fronts say 29 ft-lbs and the rear is 32.

[NAZ]

Looks like you followed the instructions. I suspect they are in error or your bolts are larger than M10 and if you follow those torque specs with the new banjo bolts you may get the same results. While you're waiting for the new bolts do some research online on torque values for the size banjo bolts you have. I've provided you with Wilwood's torque value for M10x1 size banjo bolts (you should conform for yourself) and you can check with hydraulic fitting suppliers for torque values on banjo bolts (took me less than 5-mins to find this info) just for a sanity check on the FFR supplied torque values.

Your can tighten the new ones by hand (1/4-turn past snug may be too much) and apply pressure to check for leaks. You can always go tighter but if you go too far you're hosed again. I've tightened banjo bolts lots of times by hand but you really want to be careful not to over do it with the by guess and by golly approach or you may be back to buying replacements.

Good luck, don't give up and you'll end up with a leak free joint.

[cv2065]

Thanks NAZ. With the front torque specs, wondering if those bolts are over stressed at this point as well. I was thinking that 30 ft-lbs seemed like a lot and double checked the manual a couple of times. Maybe I’ll replace those as well just for peace of mind.

[BadAsp427]

Thanks NAZ. With the front torque specs, wondering if those bolts are over stressed at this point as well. I was thinking that 30 ft-lbs seemed like a lot and double checked the manual a couple of times. Maybe I’ll replace those as well just for peace of mind.

You have and extra set of those front ones don't you!!!...

[cv2065]

You have and extra set of those front ones don't you!!!...

LOL...Oh yeah....was just looking at em...:)

[Papa]

All you really need to do for the bajo bolts is tighten enough to get a seal by compressing the copper crush washer. In the Wilwood installation document I got is says: "If using Wilwood flexline hose kit, torque banjo bolt to 15-25 ft-lbs. DO NOT exceed 25 ft-lbs."

[silver_pilate]

Same thing happened to me when following the torque suggestions in the manual. Figured out that you don't need near that amount of torque.

[cv2065]

Same thing happened to me when following the torque suggestions in the manual. Figured out that you don't need near that amount of torque.

Guess FFR needs to change the manual. I’ll send them a note. Thanks for the replies guys.

[MyBucketList]

Same thing happened to me when following the torque suggestions in the manual. Figured out that you don't need near that amount of torque.

Just had the exact same thing happen following the spec in the build manual that came with my kit in October 2021. I guess it hasn't been updated yet. :)

Very frustrating.

[StoneyCreekCobra]

Just had the exact same thing happen following the spec in the build manual that came with my kit in October 2021. I guess it hasn't been updated yet. :)

Very frustrating.

This is good to note

[BradCraig]

I just tighten those by feel. If they drip just give them a little more turn.

[Ducky2009]

My manual from early 2017 also says 29/32 lbft. I didn't go that high. Manuals mush have been off for quite some time.