1984 Pontiac Fiero 2.5L......I replaced the brake caliper some time ago and since then I get brake fluid leakage at the banjo bolt. I replaced both of the brass washers at that time, but now people are telling me I should have re-used the old ones (which I don't have any more). Does anyone have any ideas short of replacing the caliper, hose and washers with new? This would give me all new mating surfaces. I was just told I can buy a new banjo bolt. I think that would be the cheapest place to start.

Take the banjo bolt off. get some emery paper and a block of wood and sand down the surface where the banjo bolt mounts (on the caliper, not the hose). This surface is usually pitted from sandblasting. Next, sand down the copper washers. Re-assemble. If necessary use a hammer and tap on the banjo bolt a little to help seat the copper washers (just a little tap). I had to do this on a few calipers to stop them from leaking. Make sure the caliper hole stays clean (to keep filings from going in there). Flush caliper well when done.

[This message has been edited by jaskispyder (edited 04-22-2013).]

Always use new copper washers, unless you use a torch to properly anneal the old ones. New copper washers are supplied in the soft, annealed state, and they immediately work harden as they are crushed when the banjo bolt is tightened.

[This message has been edited by Marvin McInnis (edited 04-22-2013).]