04 Heritage 2wd. New calipers all the way around. New soft line to driver front. And it will NOT stop leaking. Replaced the copper washers on the banjo bolt when I put on the new soft line. Leak. Added another copper washer thinking maybe I just mashed it too much. Leak. Not just a drip either, it's a puddle under the truck. I have never had this to happen. Ever.

 

I've seen a reman with a hairline crack in it do the exact thing you speak of.

 

did you get a1-cardont calipers

 

CENTRIC 14165046 Reman from RockAuto

 

Banjo bolts have two sealing surfaces. One at the thing you're sealing to and one under the bolt head. You might be focusing on the wrong surface, check under the bolt head. Use a magnifying glass and bright light and you might see a defect.

 

Correct, BBXL. If he bought a new soft line, it should have already had both copper washers. Did you maybe think it was a spare Superdave?

As BBXL said, you should have it looking similar to this:

 

Yep, I used both new copper washers on the bolt. Just like in the pic. It just leaks like crazy. Honestly, I have never even used new washers before this truck. I always re-used the ones already on there. I will take it apart again and examine the bolt head and the mating surfaces of the soft line to see if there's something that looks wrong. It seems like it would have to be visible for it to not seal with the copper.

 

I had two problems the last time I replaced calipers from RA. First problem was with one of the new banjo bolts. It was machined poorly and wasn't drilled thru completely. Luckily I caught that before installing, otherwise fluid wouldn't have made it to the caliper.

Second problem was with the new copper washers, I couldn't get them to seal. Luckily I had another set of washers on hand from I don't know where. I got those to seal fortunately, but it took quite a bit of torque to do so. But yea, I had a tough time with the RA washers.

BTW- This was when I did 7700/Expy big brake upgrade to the truck. Parts were actually cheaper vs the junk brakes the most these F150's came with. Major difference in both stopping power and longevity.

 

Why don’t you drop a picture of the caliper? Otherwise we’re just shooting answers at the wall and hoping they stick.

 

Well it is 24 degrees here so I am delaying going out and working on this. Not gonna get any warmer for a while either. But I also don't want the master cylinder to leak dry either.