Search the Community

Looking for suggestions... I just tried installing the Motorsport Auto 4-piston brake upgrade kit (Toyota s12+8 calipers for solid rotors) and ran into trouble getting a reliable seal that doesn't leak brake fluid. I bought this kit (calipers, pads and brake lines) over a year ago and finally found time to install it during a front end rebuild. Since I can't return the kit, since I purchased it a while ago and also painted the calipers, I need to figure out a way to install the kit without spend more bucks. Here's the problem... This kit came with the banjo bolt stainless steel brake lines - even though it is evident that these calipers were not designed for this type of connection. These calipers do not have a machined flange (or even a smooth flange) where the brake line banjo bolt fitting attaches. Even worse, one of the calipers had a small casting imperfection in the caliper next to the machined bolt hole where the banjo bolt attaches. I tried filing flat the raised flange around the machine bolt hole until it was completely flat around the hole. In the process, I ended up shaving about an eighth of a inch off the flange. Now it seems that the banjo bolt is bottoming out in the caliper casting before it can be completely tightened (I used first aluminum and then brass crush washers to attempt to seal the connection). I even tried to place an additional crush washer on the fitting to see if it would seal--Not. So what do you think? Is a new caliper in order? Do you think new brake lines without banjo fittings might work? Anyone else have a similar experience?