Tundra brake upgrade, seeking help!

Currently doing the tundra brake upgrade and hitting a road block when installing wheeler's front brake lines with their included banjo bolt. For whatever reasons the banjo bolt and included two copper washers will not torque down to a point where the line doesn't have any play in it. On the other side of the truck I was able to torque it down where it doesn't have any play but the driver side is being a b***h. Any ideas? Maybe grab another copper washer for a total of 3 or 4?

 

You can drill the end of the banjo bolt out a little. You could try another copper washer. pic coming of banjo bolt mod.

 

Thank you for the advice! I am trying to mititgate drilling anything so I am leaning towards using a few more washers. I'm not a brake expert though so I don't know if using more than the two recommended washers would be bad?

 

Don't have to drill nearly as much as i did. Usually just the taper of the drill bit is enough

 

This actually sounds to me like an issue with the caliper rather than the bolt that came from Wheeler's. I've seen several calipers (including one yesterday with @Digiratus) where the threading in the caliper wasn't as deep (or otherwise inhibited full penetration) as it should have been. I think this is a result of the reman process that some vendors do on the calipers.

It was interesting because one of his had the problem, and the other didn't. Both were from Napa, which generally has high quality remans.

 

I'll add one more bit, since it looks like you have a kit and so it's probably harder to return the calipers than if you'd gotten them at a local shop.

...you can definitely try an additional crush washer and see if you can get everything to seat and seal correctly. It's not ideal for sure, but if you have no leaks after bleeding and bedding, it'll probably be OK. You'll just need to be sure to monitor it to look for leakage.

 

Yep, looks like you got the Callahan kit? I just had the same problem with mine as well. Was kinda furious. And confused as to why it wasn't working as a plug and play type deal like everyone said it was with wheelers lines. But I think @turbodb is correct regarding the reman process and some vary a lil bit. But I decided to drill them out with a 3/8" bit, which was easy. But had a helluva time getting them to stop leaking. I used thicker washers I got from parts store, and they finally stopped leaking after tightening them down pretty tight. Just take your time tho and don't just crank those suckers down too tight on first try and possibly break one. Just tiny cranks each time until they stop leaking. Test them and watch them as you bleed, as well as pumping the brakes and holding it there to see if they seep, then after bed in. Theyll be fine leaking a lil in the process tho, until you get em to stop. I had to crank one side down more than the other. Kept checking it a few days after and no more leaking. Oh and make sure you dont let your master run empty in the process!

 

He said "full penetration"...hehehe

 

Pretty frustrating I know, thanks for the reply. I finally got them to stop leaking, I had to grind down one of the banjo bolts to get it to fit correctly. Also grabbed a few new copper washers to throw on there since the others had been tightened and loosened a couple few times. Things are working really well now which is nice, a good overall mod that I'm happy I did!

 

Couple of photos from the install!

 

Dude...just post the pic's, not pdf's of pics/.

 

There you go, bud

 

aye! you got the same jack as me.

 

Did this work?

 

yep

 

I just did this with the Callahan kit and Wheelers brake lines. I felt like I was definitely tightening the banjo bolt more than I've had to on other caliper replacements I've done before. Seemed odd, but it was able to completely snug up and stop seeping fluid. If it starts up again, I might do what someone else suggested in the "yet another tundra brake upgrade thread" and get some thicker copper washers, since I too am hesitant to drill the bolts (mainly since I don't have a vice/shop right now). Would stacking multiple washers work or would it not compress properly to get an adequate seal?

 

I've been running stacked washers between the caliper and brake line for a few years now. It's basically the only fluid on my truck that doesn't leak...

 

I took your word for it and you sir were correct
It worked and I now have tundra brakes