Thread: leaky banjo bolts on front brakes ...crash

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ok i have a question i have a new set of gm calipers and banjo bolts and fittings w aluminum washers , everything fits great and tight but leaks .....does the bolts that go into caliper need sealer >>>> tuff question as you would have to see in person ......is this a common problem and what is a good torque spec if any??? im putting them super tight. doesnt seem warped either

Never use any kind of sealer on brake lines. Try a copper washer, I've never had much luck with the aluminum ones.

yep, replace with copper washers.

My son and I are building a 32 and had the same problem. I bought new bolts and I do not even know how many washers. I finally cleaned everything then put a white paper towel under the caliper and began tightening. I tightened the bolts until each time I did it I would flinch because I just knew the bolt was going to snap. I would check the towel the next day and see if they leaked. I did this for some time until they finally stopped.

Before you install, scuff the washers and the banjo fittings with 220 grit sandpaper... lay the sandpaper on a smooth, flat surface and sand the surfaces in a circular motion....

ill try the copper next time i run out to store and ill try the sanding trick as well . i would think the copper ones would seal better but also question why they would sell aluminum ones if they were this prone to leaking , but hey i bought speedway parts .....sometimes that is a shot in the dark as well ..

Guess I've never had any problems with either!!! Check the seal surface on the caliper for burrs, too. Sometimes there is a slight burr on the surface from the threading machine.....

I had a similar problem. It was caused by the fitting that the banjo bolt goes thru was contacting the caliper and not allowing the surfaces to seal. A minor trimming of the caliper at that area of contact solved the problem.

I also do not like the aluminum washers. They do not seal as well as the copper.

Magnum kit for Camaro disc brakes on solid axle.

Take note of the two recommended areas to grind for clearance.


I have a print for the 68-70 Mustang disc brake install as well.
In case anyone is interested.

thanks for the post , i already grinded the area for fitment of the banjo as it would have been facing a 180 deg the other way , i also purchased longer bolts as the ones provided only had half the threads that i can use so im gonna install them tonight and cross my fingys and see what happens

Be carefull with the longer bolts. I had a mustang 2 brake kit from Speedway with the GM calipers. The bolts bottomed out against the back of the piston in the caliper. After not gitting it to seal I removed the bolts and looked though the hole. I could see where the bolt a nicked the back edge of the piston. I ground off a little bit of the bolt and that took care of the problem.