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Tips for the Turbo Banjo Bolt Leak

11378 Views 20 Replies 9 Participants Last post by  bmxer4l1fe
My car does not leak from any other area but this damn place.
It was fixed last week, I drove it hard for 45 minutes in 5-6th gear at 5000-6000 rpm and some droplets started showing up.
When my mechanic drove it for 1 hour in the same way there were zero oil spots.

Having purchased a cool endoscope, I identified some marks in the banjo bolt area.
I took the car back to the dealership this morning.
The car was checked today for 3 hours for part alignment, for any area that might not seat properly.
They used cameras, they used light between parts, they looked around and could not see any other places where it might leak from.

The used a dye and identified that the only place the leak happens is that stupid bolt.
I have new tubes, new crushers, new seals whatever you want to call them.
They used copper, they used other materials, same result.
I am going to order a different tube from Goodridge or my brake tube manufacturer but in the meantime, I am curious of the following :

What is your secret to fixing this?
Did you get creative? If yes how?

I am so close to fixing this car ...

Everyone is puzzled.
The guys from my dealership, the guys from a second dealership, and the guys from the Factory.
Well they pretend to be puzzled.
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Thank you for the replies. I will see if I can find those magic washers.
Had a look with the endo today, there are no significant leaks yet.
Going to check in another few days.
It’s been a couple years now, wondering if you’re still active and if you found a permanent fix for this leak? This is the most comprehensive thread I’ve found and my dealer has tried 3-4 times to stop this leak since my HG recall work and timing chain cover sealant TSB years ago 🥲
im having the same issue as well.. think im going to try the "Dowty seals/washers " mentioned above.
It's almost certainly not leaking from the banjo bolt -- you should use a boroscope to get behind the engine as much as you can to inspect and try to find more oil leaking from above the turbo on the back of the engine. In my case, I found the actual source of my leak is from the head gasket near the timing chain cover back corner. This is most likely because Ford updated the head gasket TSB process to include the additional sealant at this location long after I had my head gasket TSB work done.
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