PS return fitting leaking
 

I FINALLY got a chance to finish installing my rebuilt rack today. I went to flush the system, and noticed the return line fitting has a steady drip coming from it. I put on a fresh crush washer, and still the same. What do you guys think? Is it the fitting, the bolt that connects the fitting to the rack, or the rebuilt rack? I sure would like to be done with this repair; it has dragged on for WAY too long.

there are 2 sealing washers per banjo bolt??
It might just need a little more tightening but only with new sealing washers.
Also loosen the 10mm securing bolt on the clamp that runs up the fender tighten the bajo then retighten the securing clamp
Did you put any sealant onto the washers prior to tightening the banjos
With a new rack I hope you also installed a new reservoir with fresh hoses to the reservoir

What do you mean 2 sealing washers? Isn't there just a brass crush washer for the banjo bolt? Are there small rubber o-rings that go on the bolt too in addition to the crush washer?
I have tightened the bolt down all the way; won't go no more without some serious torque, and I am not comfortable going that route since the rack is aluminum.
I did not put sealant on the return line crush washer because I knew I would be loosening it again in order to flush the system. I put it on the other and it does not leak.
I will try loosening the 10mm bolt and re-tightening the banjo; maybe the angle was not right-on when I tightened it before.
My reservoir is the metal one- it's in great shape. I have replaced the rubber line running from the pump to the reservoir, but that's it.

There are always 2 washers on a banjo - item 35 -

http://forums.pelicanparts.com/uploa...1263444924.jpg

for the banjo to seal properly use 2 new sealing washers, they are made of copper, no rubber
When you use the old sealing washers they have been work hardened and thus usually will create a leak, as the wont confor as easily as fresh sealing washers do.
If you have a steel tank then I guess that replacement isnt in the cards

Thanks once again for saving the day Stan. The problem is that I was only using 1 washer instead of 2.
The PET would had shown me this, but mine is missing right now. I have the PET saved on a jump drive that stays plugged into my computer at all times, but it disappeared 3 days ago. The prime suspect is my 5 year old son - he has a wonderful imagination and can turn anything into a toy. Who knows where he left it. Probably in his room somewhere.
Neil - Thanks for the pic, a definite help.

your welcome Neil