Hi everyone, been fixing up my cherokee for abit now, swapping parts here and there as needed. so as my front brakes were starting to fail I went ahead removing the brake pads and rotors only to find the calipers were also seized. So I purchased all the parts and began assembly, install went smooth only to find after both sides were installed that I have a leak coming from were the line and banjo bolt thread into the caliper. What could possibly be causing this leak I replaced both banjo bolts and washers, Now my conclusion is either the lines themselves or the manufactured calipers, If anyone else has had this problem or knows of a solution,your incite would be much appreciated, Thanks in advance.

 

Have someone else step on the brake pedal while you observe the exact source of the leak?

 

-.- I know exactly where its coming from just dont know why it's leaking exactly. The leak is coming from the caliper where the banjo bolt threads in and mates with the brake line,I've tried different washers and even doubled up on them, the last thing I can think of trying is filing down the caliper to make the mating surface flush, If someone else can float a solution my way it would be most appreciated

 

Filing the caliper will likely make is LESS flat. Do I understand correctly that these are new calipers? Are they rebuilt calipers?

You should have one copper washer between the caliper and the banjo fitting and one copper washer between the banjo fitting and the bolt. Also make sure the bolt is good and snug. Use a six-pointed socket so you don't strip the bolt head.

If you have everything assembled correctly and tightened down and you're sure the caliper is still leaking between the caliper and the banjo fitting, I would suspect there's a problem with the caliper and would exchange it.

 

are the bolts and banjo fittings new? If the banjo fitting is any bit out of round it will leak. Adding washers will not help as it offsets the position of the bolt to the fitting. Meaning it will raise the bolt out higher than it is designed to press against the fitting.

 

Ive assembled the brakes properly washers on both sides of the brake line mating surface, and yes they are rebuilt got em 25 bucks each,I bought new washers and banjos this morning then torqued them down to 25lbs. The leak has seemed to stop Im starting to suspect the banjo bolt itself, I thank you all for the swift responses, the only thing I have left to do is wait on my always fashionably late buddy to assist in bleeding the brakes, again thank you all!.