New brake calipers are leaking.

[Oldfart1979]

Hello
Over the past few months I have been rebuilding a 99 ranger xlt 4wd 3.0L. So far I've put in new plugs, wire set, air filter, and a few bulbs. I've also replaced on the sides the upper control arm, lower ball joint, sway bar end links, inner/outer tie rods, CV shafts, steering knuckles, hub/ bearing assemblies, rotors, pads, calipers, brake hoses, and install manual lockouts.
The passenger side calipers are fine, no leaks. The drivers side is another story. The caliper leaks where the brake hose bolts onto the caliper. I've been following the instructions. Put a copper washer on the caliper, brake hose, copper washer, banjo bolt. Hand tighten. Torque to 25 ft lbs. Just keeps leaking. I tried the old brake line; still leaks. I don't want to over turning that bolt. But what else should I do?
Any advice I'll take it

 

[Dirtman]

You got a defective caliper. Return it...

 

[Uncle Gump]

I have also used the old copper washers with some success. Does the caliper have the sealing grooves clearly in the surface? You can also try getting the banjo bolt snug and rocking the line a little to help seal the copper in the grooves. But if the sealing surface looks funky on the caliper... replace it.

 

[Oldfart1979]

I have also used the old copper washers with some success. Does the caliper have the sealing grooves clearly in the surface? You can also try getting the banjo bolt snug and rocking the line a little to help seal the copper in the grooves. But if the sealing surface looks funky on the caliper... replace it.

I think it'll be easier to just replace it.

 

[sgtsandman]

I’m with the caliper is defective crowd.

 

[PetroleumJunkie412]

Did you try cursing at it?

 

[Dirtman]

I’m with the caliper is defective crowd.

It's a good crowd, we have a pot luck dinner every Thursday

 

[Shran]

Are these remanufactured calipers? Painted/powder coated? I have seen the sealing surface rust pitted on reman calipers before. Paint/powder coat will interfere with the seal as well. Improperly sized copper washers are also a huge issue - if the hole in the washer is much larger than the banjo bolt, or the washer is really thin, it will never seal. Very common, very irritating problem with Ford in particular and most of the parts stores do not carry the correct size of copper washers.

Tighten your banjo bolt down some more if you feel like you can rule out everything I mentioned. I think I usually go way past 25ft/lbs. You have nothing to lose except time at this point.

 

[MikeG]

Were you reusing old copper washers?

 

[85_Ranger4x4]

Are these remanufactured calipers? Painted/powder coated? I have seen the sealing surface rust pitted on reman calipers before. Paint/powder coat will interfere with the seal as well.

I fought this tooth and nail with both of my reman calipers.