Banjo bolts are out!

[Chero77]

Ok, my banjo bolts are all out. I am off to get some 9/16 fine thread bolts to use as plugs. So what should I use to seal the new bolts/plugs? Factory type seals from the dealer or will locktite or something work?

Also, the banjo bolts are about 1" long. I noticed from searching old posts that many who have done this have cut the new bolts to 1/2" or so. Is this necessary or is it just a nice touch? I guess I could cut them with a dremel if its needed.

Thanks,
Dave

[Iron Horse]

I think you need to cut them in order to keep them from restricting exhaust flow.

[Sgt. Dave]

Dave, Just get some copper washers to go with the bolts & you're set!

[Crazy_Jeepman]

I cut mine to length. Then just tightened down, no sealing. Never has leaked. 3 years on them now. ;)

[Bob Barry]

This is a perfect excuse to get an angle-grinder... smile.gif

Seriously, I ran a nut down on the bolt, and held the bolt/nut with some large vise-grips and ran the cutoff wheel on it to take it down to a 1/2" long (the original banjo bolts have that collar from the AIR tubes for which they need the extra length).

If the 9/16" bolt you are using as a plug is too long, it will bottom out (the hole to the actual manifold passage is smaller than the bolt) and not seal properly. I also had to smooth out the manifold surface that the bolt head would bottom on, and while I think a washer would seal best, I've had no problem with using just a bead of red high-temp rtv around the threads before I screw it in to seal it up.

[Crazy_Jeepman]

<BLOCKQUOTE>quote:</font><HR>This is a perfect excuse to get an angle-grinder<HR></BLOCKQUOTE>
LOL I do the same thing "But Dear I need this tool to get the job done. Look at all the money I save doing ALL my own repairs and rebuilding trucks" That usually starts another string of questions from her, but I answer them as we are at the check out line with my new tool in hand :D I think she is trying to figure out why I have a small fortune in a Wagoneer that does not run. This question has been becomeing quite frequent :eek:

[Chero77]

Well, I cut the bolts to 1/2 inch as per Bob Barry's post. Seemed like the best approach. I clamped the bolts to an old chair on my balcony . . . err workshop, and cut them off with a dremal. Oh the joys of apartment life. I'll call the local dealer to see if he's got any washers or maybe just try the red rtv. After all they use that stuff in place of manifold gaskets at the factory. Just don't want to use anything that would seal them permanently, want to make sure I can restore all of the smog gear if the need ever arises. Actually, I think I could get it all back on, i.e., air pump, injection rails, diverter, EGR, and CTO's in about 2-3 hours if need be. This stuff was pretty simple on Federal '77s and not very well integrated with the engine.