How to Install Banjo Fittings

A banjo fitting closely resembles its musical instrument namesake. It consists of a hollow bolt with an integrated spherical union for fluid transfer.

Hydraulic systems rely on parts known as banjo fittings to connect their hydraulic lines safely and leak-free, thus maintaining efficiency of operation. Here is more information on these crucial components of their systems: Frequently Asked Questions About Banjo Fittings.


Banjo fittings are specifically designed for hydraulic applications. They’re commonly found in automobile braking systems and other high-pressure applications, while they also play an essential part in industrial machinery and equipment. Their compact size makes them an excellent option in tight spaces while their high-quality construction helps ensure they stand up against fluid flow pressures without leaking or cracking under pressure.

These fittings are typically constructed of steel or brass with smooth surfaces for ease of connection and removal, often painted or treated to protect them against corrosion and the elements, and come in various sizes to meet the needs of various hydraulic systems. When choosing one for yourself, make sure that factors like pressure ratings and flow rates are taken into consideration as well as possible space constraints within your system or whether multiple hoses/pipes need to be accommodated in any given system.

Banjo bolts are often employed to secure fittings to other components, as they feature an internal bore through which fluid flows and are threaded so as to screw into a receiving port on another component. Rubber O-ring seals may also provide extra seal and prevent leakage.

Tighten or loosen a bolt using a wrench, but be mindful to follow manufacturer torque specifications so as to not over-tighten and damage its sealing ring. Before connecting bolt and o-ring components it is wise to clean their surfaces thoroughly in order to eliminate dirt or grime contamination of fluid lines and ensure efficient functioning. Having a maintenance schedule set for these components is also strongly advised as corrosion and damage may arise over time.


Banjo fittings are constructed using materials chosen for their strength and durability; typically steel or brass. Furthermore, their corrosion-resistance makes them suitable for high-pressure applications as well as easy use on assembly lines or industrial settings.

Zero-Leak Gold (ZLG) banjo fittings feature two metal-to-metal seals and additional elastomeric back-up seals to provide a leak-free connection, with their primary seals located in machined recesses that maximize unit loading while minimising gaps between mating components during assembly torque applications. Furthermore, their design provides exceptional resistance against vibration and harsh environmental conditions.

ZLG banjo fittings have become widely utilized across multiple industries, from automotive and powersports vehicles to marine use and hydraulic systems – from marine engines to boats. Their superior qualities have led to widespread acceptance. They play a critical role in providing fluid power transference to actuators.

Banjo fittings play an indispensable role in numerous industries outside of automotive and hydraulic systems, not only automotive or hydraulic. For example, banjo fittings can be seen used to connect fuel delivery lines to tanks, pumps and injectors; fuel lines to tanks; brake hoses connected to calipers, wheel cylinders or master cylinders and fuel delivery lines with tanks or pumps and injectors for fuel delivery systems as well as connecting brake hoses directly.

For your system’s safety and integrity, regularly inspect banjo fittings for signs of wear or damage and corrosion. Any components showing corrosion should be replaced immediately in order to stop fluid loss as soon as possible and reduce safety risks. Keeping your system clean also reduces blockages or other potential issues in its functioning.


Manufacturing banjo fittings involves an intricate process that begins by selecting high-grade metal and cutting it into various shapes for each component, such as bolt, collar, and ring precision machined to fit together perfectly before being coated or treated to resist corrosion and increase durability. Once all the components have been assembled they are sealed using seal and washer connections to form watertight connections and create hydraulic fittings capable of withstanding high pressure, bending, rotation without leakage. The end product of all this effort is an end product capable of withstanding pressure, bend, rotation without leakage – creating hydraulic fittings capable of withstanding pressure without leakage leaking.

An easy way to identify a banjo hydraulic fitting is its distinct appearance, which easily sets it apart from other fitting types. The banjo musical instrument inspired its name. Notable characteristics of a banjo fitting include its oval-shaped body with an eye-shaped union or ring that encases the bolt; additionally, some models have pivoting ends so one or more fitting ends can be rotated or pivoted independently of other fitting ends.

Banjo fittings feature an engineered polymer sheath structure to protect fluid from contaminants while simultaneously protecting threads of bolt and reducing heat/friction between bolt and hose or tube. They’re typically found in high-pressure applications like automotive brake systems or marine equipment where tight connections with no leakages or gaps are critical, so finding a supplier with extensive inventory of hydraulic banjo parts and fast shipping/delivery is of utmost importance when selecting this type of hydraulic fitting for high pressure use.


Step one in installing a banjo fitting involves gathering the appropriate tools, such as wrenches that fit each bolt or union size. Utilizing the proper size will prevent damage to either component. Cleaning all components prior to assembly is also key since any dirt or debris on these can compromise seals and lead to leakage issues; additionally it is wise to utilize any recommended sealants or thread tape.

An integral component of banjo fittings is its bolt, which acts as the conduit through which fluid travels. Usually hollow with threaded ends to attach securely into other components, it must meet specific pressure and flow requirements before selecting its optimal bolt.

Ideal banjo bolt materials should include stainless steel or brass to maximize durability and corrosion resistance, as these materials have proven their strength under high-pressure applications and provide more corrosion resistance compared to aluminum which is vulnerable to chemical or heat degradation.

Another key component of a banjo fitting is the union, resembling a doughnut-shaped donut and giving rise to its name. The union features a hole for aligning with a bolt and an opening on one side for connecting pipes or hoses; additionally it can typically swivel to accommodate different angles while relieving stress from hydraulic lines. Finally, sealing washers protect against leakage by compressing against flat surfaces when tightening down its bolt.


Before beginning installation, ensure you have all the tools required for the task – such as wrenches that fit the banjo bolt and sealants or thread tape recommended by the manufacturer – for a successful job. Clean all of the parts first – bolt, union and washers are particularly susceptible to dirt accumulation which could compromise their seal and lead to leaks. Once clean, place two sealing washers either side of each union; these compress when tightened creating an airtight seal keeping fluid within your system and keeping any potential leaks at bay.

Once your banjo fitting is secure, use a wrench to tighten it according to its manufacturer’s specifications. Over-tightening could damage or deform washers and lead to leakage issues; under-tightening could leave an unsatisfactory fit between union and bolt, increasing chances of coming apart altogether.

Hydraulic systems can be exposed to high levels of pressure, making it essential to choose a quality banjo fitting that can withstand this pressure without leaking or failing. Look for one made with quality materials, that has undergone multiple inspections and testing for safety before installation – and be sure to secure it using both a lock nut and rubber gasket for best results.

Banjo fittings can be found in a wide array of applications, including irrigation systems and pesticide application equipment. They provide secure connections between pipes, hoses, and spray nozzles for accurate distribution of water or chemicals, heavy machinery braking systems, marine equipment, aerospace applications, heavy machinery chassis brake systems as well as being lightweight yet strong and corrosion resistant materials such as steel brass or aluminum which make up these versatile fittings.