Brake fluid leak at caliper

[Icefan71]

94 Camry 2.2. I have a brake fluid leak right at the front left caliper. Caliper is new. Fluid is coming out from the banjo bolt washers. I tried new washers of the same size, then a thicker size, and even one thick one thin. I made sure the mating surfaces were clean and I tried tightening the banjo bolt past 21 ft lbs. The threads are still good on the bolt and the caliper. Still when I pump the brake, fluid leaks out. I don't know what else to try other than maybe a new banjo bolt and/or new hose. Help please.

[Stillrunning]

I doubt the leak is at the copper washers of the banjo bolt. More than likely the hose connection to the BB. It's a 94, I'd recommend replacing all the brake hoses.

[yeahitsgottahemi]

is there any rust on the mating surfaces??? And did you take the old cooper washer off?

[Zembonez]

Check the banjo bolt. If it has any imperfections in it or is deformed at all it will leak.

[Icefan71]

The caliper and hose are new. I filed the head of the bolt where the washer goes and it got better but didn't stop the leak completely. Instead of a steady drip, its a drip every few seconds. I filed it again, but thats the best I could get it. So I went to all my local auto parts stores and I couldn't get a new banjo bolt. I have one on order from the dealer. It wont be here till Tuesday. The washers are new and the old ones are removed.

[JohnGD]

If those components are new I'd suggest that you return them get replacements under warranty. New brake hose banjos and calipers should not leak.

[Icefan71]

Caliper and hose are new. I still have the old banjo on there. I have a new one on order. The leak is between the banjo bolt washer, and hose. The other side of the hose against the caliper is fine.

[JohnGD]

So you're ordering a new banjo bolt? Not the banjo fitting because it's attached to the new hose that's already on the car, right?

You should use only 1 new crush washer on *each side* of the banjo fitting. If you use 2 then it may leak under pressure.

Usually the banjo bolt is not a problem. Something isn't right there but see if your new banjo bolt fixes it. Otherwise I'd return the caliper and hose instead of trying to sand/polish them. That's what warranty is for, and for your safety.

[mazdaverx7]

with all that's been said, i wonder if the banjo end of the hose has a small hairline crack on the mating surface. keep us updated on what you find out.

[Icefan71]

Yes, JohnGD. I have a banjo bolt on order from Toyota dealer. And yes there is one washer on either side of the hose banjo end. If that doesn't fix it, I'll exchange the caliper and hose. ANd if that doesn't fix it, there'll be a Camry parked at the bottom of the Susquehanna River.

[ajkalian]

Whenever I had replaced brake hoses/and copper washers, the ends of the brake hoses always had concentric rings on both sides and the copper washer would be crushed by the banjo bolt, deforming the copper washer into those rings making a very good seal. Toyota decided not to use that concept and went to a flat surface on the end of the brake hose.

In order for Toyota's system to seal properly, everything has to be square. The ends of the hose has to be machined perfectly parallel to each other, the caliper threads have to be perpendicular to the caliper machining surface that the brake hose mates to, and the banjo bolt has to be perfectly machined.

I had no problems with the stock Toyota hoses sealing, but yours might just be a bit off spec, and that might be why there is a small leak, even though everything is new.

Here's some pics of the stock hoses and the Autozone hoses. Oddly enough, one Autozone brake hose had the concentric rings and one didn't. Go figure. But neither of the Autozone hoses fit correctly.







.

[Icefan71]

Been thinking about what JohnGD said and I'm starting to get annoyed. New parts should fit with no problems or mods. I think I'll return my hoses (from Autozone) and get them from the dealer along with the banjo bolt. I don't really have any problems buying from Autozone, Advanced Auto, etc. But this time nothing BUT problems. I like the fact that I drive this car with no worries and I want to keep it that way.

[Icefan71]

Got a new banjo bolt on Tuesday. I compared the new one to the old one and could see anything wrong with the old one, but I put the new one in along with new washers again. Its been 3 days and everything is fine. No leak. Once again thanks for everyone's input.