I have had a fluid leak at the pressure hose to rack fitting for some time now, and I have had no luck fixing the problem. I've replaced the copper washers twice -- carefully ensuring no dirt, grit or burrs were present and leak persists. Does anyone have any tips or suggestions on what I could possibly do to fix this pesky leak?

 

aRE YOU SURE ITS THE fitting, not weeping through the hose and going downhill to the end? Mine went with a weep, but high up on the inner guard where it was obviously the hose, not the fitting.
jp 83 Euro S AT 47k

 

Mine was both a pinhole in the hp line, and a leak in the seal that is in the mainshaft cover plate.
Aren't those banjo fittings difficult to get started!
Clean everything spotlessly. Then check. It may take a few repetitions.

 

The hose is new. It also appeared that the main shaft seal was leaking a bit but I've concluded that the ATF leaking from the pressure hose fitting is blowing onto the shaft area when driving. I've observed the fluid weeping from around the fitting when steering is turned to lock while the car was on stands, its definitely the fitting. Getting the fittings started was the most time consuming part of the job -- the first time. I've learned that if you loosen the hose bracket just enough to allow movement (leaving the hoses in the bracket) the bolt will start much easier.

 

Make sure that you aren't allowing the hose to move during the final tightening. It is easy to let the hose move, putting residual torque into the hose. The heat and vibration of driving will then let the hose pull the fitting slightly loose.

You might also try taking the fitting apart and then reassembling with only one washer. Carefully bottom out the fitting (gently!) and compare the washer thickness with the remaining space, and make sure that the fitting isn't bottoming out before it gets tight.

While you are doing this, also check the space for squareness - that is, make sure that the fitting hasn't gotten cross-threaded, so that it isn't tightening squarely.