Front Brake line leaks

[NICK C]

I have a MKIV complete kit 7622. Has anyone had issues with leaking of the lines where they connect with the caliper. In particular, I have leaks at the front calipers but rear seem ok. I have changed the washers with new ones thinking they may be scored or irregular, but still leaks. I can see the leak at the end of the line on the pass side and can feel the wet line on the drivers side. Any thoughts? Thanks Nick.

[cobrajj]

On my MK3.1, I had FFR send me 2 new front braided hoses. They were both leaking at the crimped area.

[emac]

My mkIv had the same problem. They sent me two brake lines. Still leaked. Then I got out some loupes and looked closely. It was leaking between the caliper and the washer. They sent me a new caliper and it seems OK. I am dissapointed in the front brakes. One rotor was pitted and the leaks. I am thinking of ordering some high quality lines. Can't expect much when the box says "made in China".

Ernest

[Scott7644]

I had the same issues with the front brakes on my MK4 complete kit. They were leaking between the brake lines and washers. I bought 2 packs of copper assorted washers from Autozone. This fixed the problem. The rear brakes didn't leak.

[NICK C]

Thanks for the responses. I'm pretty sure the leaks are at the washer areas next to the calipers. Scott I got some copper washers at O'reillys but still leaking. I'll try some others again and see if I can resolve the prob before calling FFR. Ernest I thought of new lines also, but looking for the simplest fix first. Thanks gentlemen.

[buildit]

http://thefactoryfiveforum.com/showthread.php?4717-front-brake-line-leaks

Good luck!

[rich grsc]

If they are leaking at the washer area, you dont have the tight enough. I would not use Loc-tite.

[buildit]

Just for clarity, the Loctite 545 isn't a thread-locker, it's a thread sealant.

[NICK C]

I got some other copper washers from Autozone and so far seems to be leak free. I'm running some fuel lines now and keep looking but no leaks. Thanks for the comments gents.

[AC Bill]

First make sure that the bolt isn't bottoming out in the caliper. There are varying bolt lengths, and caliper thread depths depending on the components used. You never know, especially with the Chinese stuff.

I initially had some minor seepage from the banjo bolt area. I had new washers, so I knew they shouldn't be the problem. I hated to keep cranking on the bolt to much, for fear of it stripping, or even shearing off, but a just little more tightening was all it needed. Sometimes a slight tweak is all that's needed.

[snakeboost]

Also if the hoses have a round style banjo fitting instead of the OEM style block you may be loosening the hose by turning the steering wheel

Steve

[AJ Roadster NJ]

This isn't unique to Roadster brakes, it comes up on every forum from Blue Ovals to Bowties to Mopars. A good friend of mine, who has built MANY muscle cars, once emailed me in total frustration because his front discs were screwed up and he could not get them to work. "Where'd ya get the banjo bolts?" "Don't remember." "Go get new sets and try 'em." "Hey, that was it!!"

Banjo bolts must be used as a complete set. As soon as you start trading out copper washers you are almost certainly doomed. Mine (not from FFR, but from a forum vendor) weren't right either, but I fixed it by running down to NAPA and getting a few bolt/washer sets in varying lengths that were close. They would've let me return anything that didn't actually get threaded in, but I just threw 'em in the small parts bin. They cost next to nothing. Keep track of each set and only use the copper washers that came with any one banjo bolt.

AJ

[NICK C]

So far so good with the leaks. Thanks for the info AJ.

[Dave Lind]

An earlier Commenter (sorry I didn't note the ID) mentioned that Harley Davidson had bango gaskets that incorporated a 'washer' and a 'gasket' that worked well. HD part #41733-88 works on the master cyl.'s and HD part #41731-01 works on the front calipers. Also, a Commenter mentioned 'torque them down' to solve the problem. Turns out, at least on my Wilwood brake kit, that the master cylinder bango bolts are aluminum and not too much force (once had a boss who said I didn't know my own strength, so use your discretion) cracked one of the MC bolts at the drilled fluid cross-hole. I tried torquing the HD washer/gasket to recommended torque and split it. I'm a novice, first time builder and haven't seriously worked on a car since my 1957 VW, but my experience with HD washer/gaskets says go gentle. Solved a leaking MC plus both leaking front calipers. Finally, my NAPA 'consultant', a long time dirt track stock car racer, says that he has never had good experience with aluminum bango fitting washers, instead recommends copper washers. I don't know, as the HD gasket/washers fixed my problem and I'm not going to tempt fate, but maybe all you need are copper washers.