I am in the process of cooling system R&R (new water pump,
hoses, thermostats, remote header tank, rebuilt radiator,
etc.). I am trying to address a plugged-up air bleed which
is soaking in CLR at the moment. I must be missing
something, as the banjo bolt does not look like it is
removable. I’m sure it must be in order to replace the
sealing washers, and to clean out the air passage. The
threads seem to be larger than the opening through which
the bolt goes through in the banjo fitting. What am I
missing?–
1976 XJ12C
Oceanside, Ca. USA, United States
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In reply to a message from Tom Anderson sent Mon 6 Oct 2014:
Tom:
I am not sure what your problem is. #1 - rust #2 - creative PO (how long have you had the car?)
On my car, much newer, the banjo on top of the radiator came
off just like any bolt that had not been touched over 18
year.
Required some colorful language on my part, but it did come
off.
I did not reuse – opted out for the longer ones with the
thicker copper washers that were available through Ron.
Steve–
The original message included these comments:
I am in the process of cooling system R&R (new water pump,
hoses, thermostats, remote header tank, rebuilt radiator,
etc.). I am trying to address a plugged-up air bleed which
is soaking in CLR at the moment. I must be missing
something, as the banjo bolt does not look like it is
removable. I’m sure it must be in order to replace the
sealing washers, and to clean out the air passage. The
threads seem to be larger than the opening through which
the bolt goes through in the banjo fitting. What am I
missing?
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In reply to a message from sbobev sent Mon 6 Oct 2014:
Well, now that it is cleaned up, I think I see the
problem. There is a threaded brass bushing (like a brass
helicoil) which screwed onto the radiator tank and into
which the banjo bolt is threaded. This bushing came out
with the bolt and id firmly stuck on due to corrosion. I
see no way to remove it without destroying the threads.
I’m sure the banjo bolt can be replaced, but where can I
get a replacement bushing (BSP to ?)?–
1976 XJ12C
Oceanside, Ca. USA, United States
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Kirbert
(Author of the Book, former owner of an '83 XJ-S H.E.)
4
There is a threaded brass bushing (like a brass
helicoil) which screwed onto the radiator tank and into
which the banjo bolt is threaded.
There was no such bushing on my '83. The banjo bolt threaded
directly into the boss on the rad. Perhaps someone had to repair
yours?
And if doing such a repair, I dunno why you’d need to stick with the
BSPP. You can tap any thread you want, you just need to find a
matching banjo bolt. In fact, it might not need to be a banjo bolt
at all; you could screw in an AN fitting or some such and fab an
entirely new air bleed manifold setup. Note that you’d probably want
to keep the ejector built into the manifold on the left side.
Another possibility: Tap whatever thread you want and MAKE a banjo
bolt! It wouldn’t be difficult; find the right length steel bolt,
rifle drill it and cross-drill it. You might need to grind the head
down to a shorter height for hood clearance. You might also opt for
stainless steel or brass rather than rust-prone steel.
That fitting on top of the rad also has some extra height, IIRC, with
a long banjo bolt and a spacer. That means you could fab an adapter
that stands up and uses a short banjo bolt.
– Kirbert
Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !On 7 Oct 2014 at 7:26, Tom Anderson wrote:
In reply to a message from Tom Anderson sent Tue 7 Oct 2014:
I do not recall seeing a helicoil on mine (some 19 years
younger than yours). Must be a gift from someone been there
before…
But if you’re on this path already, as Kirby said, use another
banjo bolt and tap the hole.
Steve–
The original message included these comments:
Well, now that it is cleaned up, I think I see the
problem. There is a threaded brass bushing (like a brass
helicoil) which screwed onto the radiator tank and into
which the banjo bolt is threaded. This bushing came out
with the bolt and id firmly stuck on due to corrosion. I
Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !
Kirbert
(Author of the Book, former owner of an '83 XJ-S H.E.)
6
I do not recall seeing a helicoil on mine (some 19 years
younger than yours). Must be a gift from someone been there
before…
Are we sure it’s a helicoil? Might it be that you just stripped the
threads and they came right out with the banjo bolt?
– Kirbert
Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !On 7 Oct 2014 at 8:58, sbobev wrote:
In reply to a message from Kirbert sent Tue 7 Oct 2014:
No, it was definitely a threaded bushing. The good news is
that whomever previously worked on the radiator used a
female soldered insert fitting which is 1/4’’ NPT. I have
been playing with brass elbows (1/4’’ NPT x 1/4’’ barb or
5/16’’ barb) and then use high temp tubing instead of the
steel line which is plugged solid somewhere along its
length. Another option per Kirby’s suggestion would be an
-AN fitting and reinforced hose, although that might be
overkill. I think that an ell may just be less subject to
plugging than a banjo fitting in the long run, and does not
seem to be much taller in profile. I guess what I assumed
was original was just another KLUGE!–
1976 XJ12C
Oceanside, Ca. USA, United States
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Hmm that XJ12C doesn’t happen to be signal red does it? With a giant sliding steel sunroof?
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Ah, good, I’m off the hook. When you said kludged XJ12C I instantly felt guilty. Some poor soul has my car
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