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Front brakes: cant get these copper washers to seal

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Old 07-12-2014, 06:39 PM
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Exclamation Front brakes: cant get these copper washers to seal

I just did the brakes on an '05 DGC; new calipers, pads and rotors. Used the new copper washers that came in the box of calipers. One washer on either side of the brake line block. This is the first time I've ever had this issue but BOTH sides will NOT seal. I've pulled the bolt several times to inspect the surface of the bolt head, caliper sealing surface and block at the end of the brake line. All surfaces appear normal and clean. Reassemble and bleed and they start to drip.

This is on BOTH sides, not just one. I thought I finally had it sealed toward the end of the day yesterday but I inspected them today and both show signs of drippage.

any ideas???
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Old 07-12-2014, 10:51 PM
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I did a front brake job on my '03 a few weeks ago, and had bought pads and rotors, planning to not replace the calipers. But then a bad caliper piston showed up, and I didn't want to mess around with rebuilding it, so I went to Autozone and picked up a Duralast reman caliper. Turns out the washers that were included with the caliper were just slightly too large. The difference in size was very little, but the new washers were just large enough to not be able to drop into the recess of the caliper brake line fitting. I figured that reusing the old ones would probably be ok, and with no leaks, that appears to be true.
I know for certain that those replacement washers would have leaked. So could this also have happened to you? Did you compare the old washers to the new ones?
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Old 07-14-2014, 10:45 AM
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Originally Posted by cv2003 View Post
I did a front brake job on my '03 a few weeks ago, and had bought pads and rotors, planning to not replace the calipers. But then a bad caliper piston showed up, and I didn't want to mess around with rebuilding it, so I went to Autozone and picked up a Duralast reman caliper. Turns out the washers that were included with the caliper were just slightly too large. The difference in size was very little, but the new washers were just large enough to not be able to drop into the recess of the caliper brake line fitting. I figured that reusing the old ones would probably be ok, and with no leaks, that appears to be true.
I know for certain that those replacement washers would have leaked. So could this also have happened to you? Did you compare the old washers to the new ones?
New washers appeared to be the same size as the old ones. In fact after pulling the brake line for the 4th time I decided to clean up the old ones and reuse them thinking it was a size thing also. Still leaked.

Today I will buy new copper washers and new banjo bolts and see if that fixes anything. Other than that I'm at a loss...
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Old 07-14-2014, 03:42 PM
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Well, that is hard to figure. I tightened to spec using a torque wrench - did you also? I'm no mechanic, and figure it's better to go by the book spec than just guess how tight to go. But since you probably tried tightening it up some more after it leaked, that's probably not the reason either.
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Old 07-14-2014, 03:42 PM
 
 
 
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