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TR4/4A Oil Pressure Banjo Nut is Leaking

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KVH

KVH

Obi Wan
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I put new copper washers on the stud and housing, on each side of the banjo nut at the oil pressure line and housing. It appears the one on the housing side is leaking rather badly. I don't want to over-tighten that cap nut fitting.

I'm actually not sure there ever was a copper washer on the housing side. I'm wondering if I should've just installed one on the outer side. My banjo nut fitting is, itself, copper. Is the problem that washer I added? The Moss parts diagram shows it, and I ordered it like a good lad, but my banjo nut fitting never leaked before. When I took the whole thing apart I heard a clanging on the floor but could only find one copper washer and that has me wondering.

Should I try gasket sealer or a thin gasket?

Any help on this latest? Thanks
 
Some sealant wouldn't hurt, but it shouldn't be leaking "badly" even without. I'd pull it back apart and look for the cause. Perhaps there is a burr or something? Perhaps the new copper washer isn't flat or doesn't fit right? ISTR there is an area there where the surface of the casting was faced around the hole, the washer has to fit inside that area.

And if it seals up without the washer, then maybe just leave it out. It's only there to seal the joint. But I'm pretty sure that banjo is a copper alloy (brass or bronze) rather than pure copper. It is harder than the washers are.
 
If I remember the one washer is bigger than the other, and yes I would use a little sealer plus I noticed on my last rebuild I had to tighten them up more than I wanted, but it did stop.
 
Is there a torque spec on that oil stud fitting? What a disaster it would be to strip that!!!!
 
My book says 22-24 ftlb.
 
I think the nut is iron based because I have seen them rust red, but the little cap on the nut might be a lighter tin. You might try a different nut, perhaps the oil is not leaking at the washer. I hate it also when the studs strips, but I think if you double nut the stud with a lock washer between the 2 nuts it will back right out, and if it is stripped some vise grips will turn it right out. I remember taking a ½ drive 6 point socket and putting some force there before it stopped leaking. One thing I do when I have an oil leak, and I am concerned about how the oil is getting out is first wipe the area over with some solvent or spray some kitchen cleaner stuff let that dry and the take some baby powder and fog some powder on the area then start it up. The powder will turn brown at the source of the leak.
 
I'm pretty sure I have it about 25lbs, not too high. I can't seem to get my torque wrench to fit in there, but I'll try again and report back. The leaking has been "controlled" to about 15 drops after parked.
 
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