Caliper rebuild

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Apr 22, 2024 | 12:13 PM

jp0469

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From: SE Mass

Caliper rebuild

I'm about to rebuild the front calipers on my Road King due to some stickiness. What tricks are there for not having all the brake fluid leak out at the banjo fitting once the caliper is removed? I saw a video where a guy put an 8mm bolt through the banjo fitting with a washer on each side and a nut to seal it off. However, it still leaks; just a little slower. I was thinking maybe a scrap piece of hose that is slightly larger than the ID of the banjo fitting. Forcing it in should hold back the fluid?

Last edited by jp0469; Apr 22, 2024 at 01:46 PM.

Apr 22, 2024 | 01:15 PM

GOGOBECK

Road Warrior

Joined: Apr 2018

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From: Moneta, Virginia

My “Mighty Vac” came with some round tapered rubber plugs. For years I wondered why they came with the vacuum pump until I needed to remove a caliper.
I think you can find them at most hardware or home improvement stores.

You could also shape a wine cork for the task!

Last edited by GOGOBECK; Apr 22, 2024 at 01:17 PM.

Apr 22, 2024 | 01:46 PM

jp0469

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From: SE Mass

Quote:

Originally Posted by GOGOBECK

Good suggestions. I have a knock off Harbor Freight Mighty Vac and it did come with some extra bits. Lowes or Home Depot might also have some random tapered plugs that could work.

Apr 23, 2024 | 07:42 AM

LQQK_OUT

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Joined: Nov 2006

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From: East Coast, USA

Pickup an assortment of vacuum caps at an auto store and use one of them to plug the banjo bolt.

Last edited by LQQK_OUT; Apr 23, 2024 at 07:58 AM.

Apr 23, 2024 | 08:21 AM

Crazy

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From: Albuquerque, NM

I just let the old fluid drain into a container. I figured it I was rebuilding the calipers anyway I wanted a completely flushed system with completely new fluid when I was done.

Apr 23, 2024 | 09:21 AM

jp0469

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From: SE Mass

Quote:

Originally Posted by Crazy

I just let the old fluid drain into a container. I figured it I was rebuilding the calipers anyway I wanted a completely flushed system with completely new fluid when I was done.

I considered that too but I'd prefer to use new fluid to flush out the old without introducing any air into the system. Much easier to bleed that way.

Apr 26, 2024 | 08:41 PM

sab4

5th Gear

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Apr 30, 2024 | 02:05 PM

ridingout

Road Captain

Joined: Aug 2018

Posts: 707

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From: Indiana

I use a nut and bolt with a o ring on both sides to seal the hose.

Apr 30, 2024 | 02:32 PM

#10

Uncle G.

Seasoned HDF Member

Joined: Jun 2010

Posts: 9,332

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From: Upstate New York

Quote:

Originally Posted by jp0469

I considered that too but I'd prefer to use new fluid to flush out the old without introducing any air into the system. Much easier to bleed that way.

Once you’ve disconnected the caliper you’ve already introduced air into the system. There’s no way to avoid it. Even if you could block the line there wlll be air in the caliper when you reassemble the brake line and bubbles will rise up the line.