HELP PLEASE! I recently installed power steering lines and I had to use a banjo bolt because the other fitting was hitting the back of my alternator (ls swap)

The problem is it leaks like crazy (at the bottom crush washer looks like), between the rack and washer.

It is as tight as I can get it. I don't want to over tighten and break the fitting. Both crush washers (top and bottom of bolt are "crushed")

Should I use teflon tape? new copper instead of aluminum crush washers? Any other suggestions

I used these 2 parts to thread into the high pressure side:

977606ERL banjo

997592ERL bolt with aluminum crush washers

 

Orb fittings require an O-Ring. It doesn't seal like the AN. Where is your O-Ring?

 

Get what you need here or another place of your choosing.
http://pressureconnections.com/custo...-Ring_Boss.pdf

 

hmm great idea but these fittings do not have o-rings?

Project V8 RX-7: Part 10 - Power Steering

Also the pez power steering lines did not come with o ring on high side either

At the (3:24 mark)

 

The Banjo is not AN where it threads in, it's ORB. It needs an o-ring due to the pressure. Go to that video again and listen beginning at 5:06. I don't know what your set up is but if it's leaking it needs an O-ring in my opinion. It's really no different than garden hose threads and those use an O-Ring also.

He says it's not needed if running a low pressure pump/restrictor. Guess you need it or it wouldn't be leaking? Are you running the restrictor? Is the Pulley for the PS pump under driven?
I can't see any better solution for you and it looks like the simplest of one.