Stupid brake question before I do something stupid

Dom1 · January 18, 2016, 01:56:14 PM

Just cleaning/servicing my brake calipers on the trusty DR and the crush washer at the line has pretty much bonded with the body of the caliper.

I can't shift it so I am thinking I am left with three choices.

1. Leave it as is fit a new crush washer on the other side of the banjo and hope for the best.

2. Fit a new crush washer to both sides of the banjo meaning the caliper side has two in the hope that the new washer will make up for any deficiencies in the old one.

3. Just hack away at it until the old one comes off. Heat/cold etc.

Not keen on 3. due to how much it has bonded, reckon 1. would be OK probably, would rather do 2. but think this could be worse than 1.

Thoughts?

Green_Ninja · January 18, 2016, 01:59:29 PM

you need to remove the old crush washer, carefully see if you can get a stanley blade or similar under the outside edge of the washer if you can it should then come off quite easily. The 'bodge' is to use 2 new crush washers one on either side of the banjo BUT we are talking brakes and you shluld never ever 'bodge' brakes.

You knew the answer before you asked really didn't you

Dom1 · January 18, 2016, 02:07:09 PM

Have tried to remove it but will give it another go.

Just don't want to damage it too much if I then have to go to 2.

Alzo · January 18, 2016, 02:19:22 PM

A wee blow over with a heat torch may well be the answer to achieve separation.

Green_Ninja · January 18, 2016, 02:27:41 PM

Quote from: Alzo on January 18, 2016, 02:19:22 PM
A wee blow over with a heat torch may well be the answer to achieve separation.

try this as well but put the banjo bolt in to protect the threads

AndyC · February 17, 2016, 07:52:53 AM

Is the washer copper or alli ?

Tiiimmmaaayyyy · February 17, 2016, 08:10:58 AM

If it's copper use some heat on it as it will expand more than the metal used in the caliper. That should brake the bond. See what I did there?

AndyC · February 17, 2016, 08:55:57 AM

If you use heat make sure you replace them with new ones, in fact for the 10p they cost you should always fit new.

I would carefully use a centre punch on the side (edge) of the washer, with the calliper well supported give it a gentle tap with a hammer.

Dom1 · February 17, 2016, 10:03:50 AM

Existing washers are ali, had the same issue on the front caliper.

Tried heating with a blowtorch but no dice, plumped for option 2 with 2 new copper washers.

All back on and bled with no leaks so far.

WizzBang · February 17, 2016, 11:42:54 AM

If you need help and things sorting properly, you know where I am, I'm pretty good with brakes.