As above, did the front brake pads a while back, needed to dismantle the left front caliper because the boot had come out of its caliper body groove and the piston would not retract enough to make room for the new pads. This needed the caliper to be removed from the brake line.
Reused the copper washers at the joint, but they now leak. Manual says 29 Nm on that bolt and new washers needed.

Any idea what size these copper washers are? Getting brake fluid all over the inside of the wheel and tyre, not a pretty sight. lol Lost about 1 cm of fluid out of the reservoir.

I have never had a problem with reusing copper washers. Is it possible there is a piece of dirt under one or is there a ridge around the edge formed by the compression of the bolt and the washer is now not seating in the same place ? Also, are the copper washers the same size (I can't rememeber) just in case you have mixed them.

The next thing to do is to anneal the washers and make them soft again. Heat them up on a gas stove to cherry red and let them air cool as slow as possible.

Did you put the copper washer between the brake line and the caliper or the brake line and the bolt?

The washers should be M10 washers with about a 16mm outer diameter. Maybe 1.2 thick? Should be available from a bearing place or a brake specialist?

I have never had a problem with reusing copper washers. Is it possible there is a piece of dirt under one or is there a ridge around the edge formed by the compression of the bolt and the washer is now not seating in the same place ? Also, are the copper washers the same size (I can't rememeber) just in case you have mixed them.

The next thing to do is to anneal the washers and make them soft again. Heat them up on a gas stove to cherry red and let them air cool as slow as possible.

Reused copper washers before too, just these don't want to co operate. lol Probably a bit of dirt as you say. Try to get new ones first.


Did you put the copper washer between the brake line and the caliper or the brake line and the bolt?

Yep, 2 washers one each side of the brake hose end.


The washers should be M10 washers with about a 16mm outer diameter. Maybe 1.2 thick? Should be available from a bearing place or a brake specialist?

Ta! Just the info I was looking for! Will go shopping (in the wife's car) today.

Excellent. Well the washers are available from Repco and I can confirm what Skapper says, that is the right size. Hopefully it's a quick and easy fix!

Went to the local parts shop and bought some washers, but no go. Turns out the outside diameter of the washer is important too, got to fit inside a recess in the caliper.
Cleaned, reassembled and bled then tested - leaked. Mmmmm - repeated this several times, until it came good - bled, reservoir topped up, seems to be ok now. Bit of invisible dirt most likely, doesn't help working on a dusty carport floor. Was thinking damaged brake hose or cracked caliper at one stage. lol

Need to keep an eye on it though. Full left lock on the steering wheel, under with a torch, easy as.

If it acts up again I will try to get the right washers, if unavailable a pair of calipers complete with hoses are on the shopping list for U-Pull-It.

I can send you washers if you like. I have stacks of them.

I can send you washers if you like. I have stacks of them.

Thanks! I will check out Supercheap, Repco etc first, but keep you in mind. Seems to be sorted at the moment.

Just grab em from any brake shop Max....thats how i 've bought mine.....Mitsu & Brembo types.

Got some on order from my local friendly Mitsu dealer. Right next door to the MSY computer shop that I was visiting anyway, thought I'd call in - Mitsu rarely gets my money these days. lol

Once I got those I can get more from the local brake shop. They seem to be happier when I can show them a sample of what I'm after. lol

Leak has definitely been cured, but it doesn't hurt to have them as spare parts. (Got a whole cupboard full, postie delivery added an ignition coil to the stockpile today. lol)