We have noticed some small hydraulic leaks at the clutch slave and brake line connections wherever a crush washer is used. We are utilizing the correct copper "crush" washers and tightening torque. Even after applying 20 percent more than specified torque, the leaks continue. Like many parts and supplies we have bought in recent years, we thought that the washers might be defective, that is perhaps the copper in present day washers might be too hard. We may try to anneal one of the copper washers to see if this affects and improvement. Also, we are considering aluminum or even nitrile faced, SS sealing washers in order to remedy this nuisance. However, I wanted to first ask for any sage advice that might be available on this forum.

Thanks

Are you using new or old "crush" washers? To be honest, I've reused dozens of original washers over the years during brake jobs and have never had a problem with leakage! So perhaps your theory of new ones being too hard has some merit?

Andy: I try never yo reuse them, they are new. We are using silicone. Would that make a diff?

I'm with Andy, I normally reuse the old ones unless they are damaged. I would be checking that the sealing surfaces are perfect, maybe touch the washer up just a bit with fine emory cloth on a flat surface; and make sure the fitting is not bottoming in the threads before crushing the washer.

Silicone does seem to be a bit harder to seal, but not by much.