Brake Line Routing Fluid Leak – 2020 Ram 4500 & 5500

January 20, 2021 NHTSA CAMPAIGN NUMBER: 21V016000

Brake Line Routing Fluid Leak

A worn rear brake caliper flexible line may cause brake fluid leakage, which may result in a partial or complete loss of the rear brakes, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V016

Manufacturer Custom Truck And Body Works

Components SUSPENSION, SERVICE BRAKES, HYDRAULIC, SERVICE BRAKES

Potential Number of Units Affected 6

 

Summary

Custom Truck And Body Works is recalling certain 2020 Dodge 4500 and 5500 vehicles. In the affected suspension systems, the rear brake caliper flexible line may have been routed so that it contacts a suspension component, possibly causing excessive wear and a loss of rear brakes.

 

Remedy

Custom Truck And Body Works will notify owners, and dealers will repair the affected suspension systems, and rear brake caliper flexible line, free of charge. Owners may contact Custom Truck And Body Works customer service at 1-706-553-9178. Custom Truck And Body Works number for this recall is 20E-031.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 


Ram 4500/5500 Brake Line Modification

Description of issue:

Ram 2019-2020 4500/5500 vehicles equipped with a LiquidSpring rear suspension may have a shortened brake hose(s) which could cause the hose to be taut, adversely contacting suspension components and causing chafing on the brake hose(s).

 

Chassis Affected:

MY 2019-2020 Ram 4500/5500 Cab Chassis.

 

Suspension Kit and Serial Numbers Affected:

Kits: DS135RS3A, DS135RS3AF, DS135RS3-DM S/N’s: 2010398-2013191

 

Kits: DS135RS2A, DS135RS2AF with conversion kits for 2019-2020 chassis. S/N’s: 2007563-2012863

 

Component Identification:

Use the below pictures to identify if the modification is already performed.

 

Driver Side Brake Line – Original Factory Banjo Mounting (Modification Required) Driver Side Brake Line – Modified Banjo Mount

(Modification Performed)

Passenger Side Brake Line – Original Factory Banjo Mounting (Modification Required) Passenger Side Brake Line – Modified Banjo Mount (Modification Performed

 

If the brake line is identified as the Original Factory Banjo Mounting, the brake line mounting must be modified with the Modified Banjo Block, Banjo Bolt, and New Crush Washers.  Follow modification instructions outlined below for installation of Modified Banjo Block for both Driver and Passenger side.

 

Inspection Instructions:

Inspect the brake lines for any wear on the flexible brake line, See Figure 1.  If any wear is found on the brake line (not the protective spiral wrap), it must be replaced.  Do not proceed with above modification and contact LiquidSpring for additional kit P/N: 11871, to replace brake line.

 

Modification Instructions:

NOTE:  The following procedures should be used in conjunction with OEM Hydraulic Brake service instructions and procedures.

  1. Locate the two (2) banjo bolts, eight (8) crush washers, and two (2) banjo blocks included in kit, P/N 11849.
  2. On the rear axle, locate the LH Rear brake outer flexible hose.

 

  1. Remove the banjo bolt and crush washers from the LH caliper and only discard washers.

 

Note: Prop up brake line to minimize fluid loss.

 

  1. Install the provided banjo block and crush washers to the caliper using retained banjo bolt from Step 3, See Figure 4– Torque banjo bolt to 25 ft-lbs.

 

  1. Install the Driver side OEM brake banjo mounting with the supplied crush washer and banjo bolt to the banjo block. Orient as shown in Figure 5. Note: Banjo fitting may be rotated to provide optimal clearance between flexible hose and surrounding parts
  2. Torque banjo bolt to 25 ft-lbs.

 

  1. Follow steps 2-4 for the RH side.
  2. Install the Passenger side OEM brake banjo mounting with the supplied crush washers and banjo bolt to the banjo block. Orient as shown in Figure 6. Note: Banjo fitting must be oriented to provide optimal clearance between flexible hose and surrounding parts
  3. Torque banjo bolt to 25 ft-lbs.

 

  1. Bleed the brake system. Follow OEM specified brake bleeding procedure. Use Manufacturer specified brake fluid as marked on the vehicle reservoir cap.

 

NOTE:  A pressure bleed system may be used to simplify one-man operation.  See Figure 7.

 

Contact Information

The LiquidSpring contact information is:
Phone: 765-474-7816 – Dial #1 for Customer Service
8:00 a.m. – 5:00 p.m.
Email: service@liquidspring.com

 

D11848

 


Ram 4500/5500 OE Brake Line Replacement

Description of issue:

Ram 2019-2020 4500/5500 vehicles identified as having wear on the brake hose(s) from contacting LiquidSpring components require replacement of OE brake hoses.

 

Parts List:

Below is a list of components required for the procedure.

Parts included in kit p/n: 11871
ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION
1 2 10003-004 HB 1.00-8×6.50, Gr 8 8 2 10804-002 Spiral Cable Wrap
2 2 10006-004 HFW 1.00 9 2 10874-350 HFB 5/8-11×3.50, Gr. 8
3 2 10012-003 LFN 1-8, Gr. G 10 2 11102-350 HFB 3/4-10 x 3.50, Gr. 8
4 2 10012-008 LFN 5/8-11 Gr. G 11 4 11392-001 Crush Washer, Copper
5 8 10012-012 LFN 3/4-16, Gr. G 12 1 11875 Hyd. Brake Hose, Dr Side
6 2 10012-014 LFN 3/4-10, Gr. G 13 1 11876 Hyd. Brake Hose, Pass Side
7 4 10064-006 U-Bolt, ¾-16 x 5.19 x 8.03 14 1 D11870 Instructions

 

 

Parts included in kit p/n: 11849
ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION
1 2 11829-001 Banjo Block 3 2 11391-002 Banjo Bolt
2 8 11392-001 Crush Washer, Copper 4 1 D11848 Instructions

 

 

Modification Instructions:

NOTE:  The following procedures should be used in conjunction with OEM Hydraulic Brake service instructions and procedures.

NOTE:  Instructions outlined in this document supersede instructions included in kit 11849.

IMPORTANT:  Ensure LiquidSpring suspension is off and fully depressurized when servicing suspension components, with frame and axle supported on jack stands. 

NOTE: Contact LiquidSpring Customer Service for additional information depressurizing the system if needed.

  1. Disconnect power to the LiquidSpring system by pulling the 80A fuse located at the battery.
  2. On the rear axle, Remove the lower axle clamp and associated hardware, discarding hardware. Do for both driver and passenger side. (Remove U-bolts, lower strut bolts, 5/8 tie bolt, and 1” lower control arm bolt.)
  1. Locate and remove the OE brake hose identified as being worn. Discard brake hose and crush washers. Retain banjo bolt.

 

IMPORTANT: Verify that the brake hose is not twisted or kinked before tightening the fitting bolt.

  1. Position the new replacement brake hose to the axle brake line junction block.
  2. Torque brake line junction block flare nut to 15 ft-lbs.
  3. Install the provided banjo block and crush washers to the caliper using retained banjo bolt from Step 3, See Figure 2.
  4. Torque banjo bolt to 25 ft-lbs.

 

  1. Install the replacement Driver side OEM brake banjo mounting with the supplied crush washer and banjo bolt to the banjo block. Orient as shown in Figure 3. Note: Banjo fitting may be rotated to provide optimal clearance between flexible hose and surrounding parts
  2. Torque banjo bolt to 25 ft-lbs.

 

  1. Follow steps 3-6 for the RH side.
  2. Install the Passenger side OEM brake banjo mounting with the supplied crush washers and banjo bolt to the banjo block. Orient as shown in Figure 4. Note: Banjo fitting must be oriented to provide optimal clearance between flexible hose and surrounding parts
  3. Torque banjo bolt to 25 ft-lbs.

 

  1. Install lower axle clamp with hardware as shown in Figure 5.

 

  1. Place the LH Axle Cradle under the axle and loosely attach to the Axle Seat using the 5/8” hardware.
  2. Slip the 3/4” U-bolts into position. Lightly tighten u-bolts.  Repeat installation for RH side.
  3. Torque, the U-bolt nuts evenly in an X-type pattern in 4 stages:   Stage 1: Tighten snug only.
    1. Stage 2: Torque to 100 ft-lbs.
    2. Stage 3: Torque to 200 ft-lbs.
    3. Stage 4: Torque to 300 ft-lbs].

 

Note:  U-Bolt Torques for Dry Fasteners.  Reduce torques 20% for use with AntiSeize.

 

  1. Torque 5/8” fastener to 172-210 ftlbs.
  2. Install 3/8” spiral wrap around flexible brake lines where they attach to the brake calipers, both Driver and Passenger side. Make sure the brake lines are routed so they don’t chafe any surrounding components.

 

  1. Re-attach both driver and passenger struts to Lower Axle Seats using bearing spacers and NEW 3/4-10 hardware.
  2. Torque 3/4” strut fasteners to 275320 ft-lbs, Dry.
  3. Re-attach lower control arms to Lower Axle Seats.

 

  1. Raise or Lower Axle until Design Ride height is achieved. Ride Height is approximately when the CL of axle to bottom of frame is 10-1/8”, See Figure 8.

 

  1. Torque 1” Fasteners to 600 ft-lbs, Dry.
  2. Reinstall 80A fuse and reconnect power to the LiquidSpring system.
  3. Bleed the brake system. Follow OEM specified brake bleeding procedure.  Use Manufacturer specified brake fluid as marked on the vehicle reservoir cap.

NOTE:  A pressure bleed system may be used to simplify one-man operation.  See Figure 9.

 

Contact Information

The LiquidSpring contact information is:
Phone: 765-474-7816 – Dial #1 for Customer Service
8:00 a.m. – 5:00 p.m.
Email: service@liquidspring.com

 

D11870 Rev A

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
RAM 4500 2020
RAM 5500 2020

 


5 Associated Documents

Recall Acknowledgement

RCAK-21V016-3922.pdf 645.621KB

RCAK-21V016-3922

 


Defect Notice 573 Report

RCLRPT-21V016-2981.PDF 216.135KB

RCLRPT-21V016-2981

 


Manufacturer Notices(to Dealers,etc)- Liquid Spring’s 573 Defect Information Report

RCMN-21V016-8121.pdf 220.112KB

RCMN-21V016-8121

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V016-1223.pdf 624.937KB

RCMN-21V016-1223

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V016-1607.pdf 586.139KB

RCMN-21V016-1607

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V016&docType=RCL

 


 

Bestseller No. 1
MOSTPLUS Universal Disc Brake Caliper Wind Back Tool and Piston Compression Sets-26 Pieces (Red)
  • Package Includes --- 18 Adapters which fit a variety of modern car wth 2X Thrust Bolt; 2X Retaining Plates; 2X Brake Caliper Hooks; 1 Pair of Gloves
  • Durable Structure --- Designed with sandblasted #45 carbon steel construction of MOSTPLUS brake caliper tool to ensure corrosion resistance and longer service life
  • Application --- Ideal for 4 wheel drive cars/trucks
  • Feature --- 26PCS kits rotates piston back into caliper for fitting of new brake shoes and pads
  • Note: box's color may vary
SaleBestseller No. 2
FIVE BANANAS Brake Caliper Press Tool, Car Ratcheting Brake Caliper Piston Spreader Press Tool with 2 pcs Steel Plates, Red
  • 【Fit for Disc Brake】 The brake caliper press tool is equipped with two groups of push boards: 7.01x2.36 inches and 4.53x2.17 inches, Suitable for most single and twin pistons floating calipers, twin and quad pistons fixed calipers or some sextuplet pistons fixed calipers (Just make sure the piston calipers space can accommodate the spreader)
  • 【Working Principle】The spreader can spreading to push the boards or retracting when finished it. (Ajust by the switch). In expanded mode, the centrally located ratchet screw creates uniform thrust to the push boards that can quickly push several pistons in the caliper at the same time. Effectively save energy and greatly improve efficiency.
  • 【How to use】Make the push boards both sides Centralized Alignment the pistons, let both sides of the push boards be forced at the same time (press both sides to assist in starting until push boards press the pistons), swing the handle until the push boards press the pistons to the suitable position, last, ajust the switch, retract the boards to remove the spreader.
  • 【Size Reference】Two groups of push boards size: 7.01x2.36 inches and 4.53x2.17 inches; Telescopic range: fully retracted: 1.88”, fully expanded: 3.03”.
  • Two-Year Customer Service for Five Bananas Brake Caliper Tool. Pls email us first when you have any problem, we promise will provide the best solutions.
Bestseller No. 3
8MILELAKE Disc Brake Caliper Compressor Wind Back Tool 24pc Professional Disc Brake Caliper Tool Set
  • Ideal for 4 wheel drive cars/trucks
  • Includes left and right handed thrust bolt assemblies
  • The kit includes 18 adapters which fit a variety of modern car brands
  • 24Pc kits rotates piston back into caliper for fitting of new brake shoes and pads
  • Storage case and a pair of gloves included.
SaleBestseller No. 4
Lisle 25750 Dual Piston Brake Caliper Compressor
  • Compresses Dual Brake Pistons Simultaneously.
  • Squeeze the tool handle until the plunger contacts the inboard brake pad.
  • Continue squeezing to compress both pistons.
  • Makes dual piston pad replacement a simple job.
  • Patent: 7,076,850
Bestseller No. 5
Orion Motor Tech 24pcs Brake Caliper Tool, Heavy Duty Brake Caliper Compression Tool Caliper Piston Tool for Brake Pad Replacement Reset, with Thrust Bolt Assemblies Retaining Plates 18 Disc Adapters
  • UNIVERSAL COMPATIBILITY: This 24-piece brake caliper tool set by Orion Motor Tech includes 2 retaining plates, left and right thrust bolt assemblies, and 18 adapters to fit hundreds of domestic and import vehicle makes and models and give you everything you need to service your brake pads
  • EASY OPERATION: Attach the plate to the handle, select the disc adapter that fits your vehicle, then simply turn to rotate the pistons back into their calipers to clear your pads; embedded magnets in each thrust bolt assembly easily hold your drive keys and adapters in place during use
  • HEAVY-DUTY MATERIAL: This set of brake caliper compression tool is crafted from structural-grade 45# steel with industry-leading technology to offer superior strength and durability; the protective sandblasted surface further enhances its wear and corrosion resistance
  • CONVENIENT STORAGE: The blow-molded ABS case of this brake piston compressor tool kit comes with pre-sized and labeled slots for easy organization, storage, and transport between jobs
  • SATISFACTION GUARANTEED: This disc brake caliper tool set is backed with its strong warranty and Orion Motor Tech's usual friendly 24/7 customer service, ensuring that you'll be able to use this kit for years to come!
Bestseller No. 6
Thorstone Master Disc Brake Caliper Tool Kit, Car Brake Piston Compressor and Wind Back Tool Set for Automotive Brake Pad Replacement, 24pcs(Black Case)
  • 🚖UNIVERSAL & PROFESSIONAL - The heavy duty brake caliper compression tool kit includes 18 adapters fitting most of vehicles makes and models including American, European, and Japanese. See the Product Description section below for a more complete list.
  • 🚖EASY OPERATION - The auto brake piston rewind tool set also includes 2 hand thrust bolt assemblies(right & left). For brake pad and shoe replacement and rotating pistons back into the caliper on your car, truck or 4 wheel drive disc brake vehicles.
  • 🚖DURABLE MATERIAL - 45# Carbon steel construction with rust-proof blasted finish, all components are designed for repeated use with high quality materials. Hand thrust bolt has magnetic design to prevent disc adapters from falling off.
  • 🚖EASY TO CARRY & STORE - After completed the job perfectly with the corresponding disc adapters and retainer plates, the ABS blow-molded case with pre-sized slots for each component storage and transport while lengthening the life of the brake caliper spreader kit.
  • 🚖100% SALE SUPPORT - We back up all products for life, 24*7 fast response customer service free all your concerns. Sincerely thanks for your support to THORSTONE!
Bestseller No. 7
BILITOOLS Disc Brake piston tool
  • Special disc piston tool with 6 unique bit configurations to engages caliper piston.
  • Special tool to make your brake job quick and simple.
  • Disc brake piston tool to rotate disc brake pistons back into the cylinder bore for the installation of new brake pads.
  • Suitable for rear disc brakes on vehicles where an outomatic adjusting parking brake mechanism is part of the disc brake caliper.
  • Use with 3/8" drive ratchet and extension bar.
SaleBestseller No. 8
Brake Caliper Compression Tool 360° Brake Caliper Press Tool Ratcheting Brake Caliper Piston Spreader Tool With Double Caliper Hangers Brake Piston Compressor Tool By GallopMax,Blue
  • 【𝐖𝐇𝐀𝐓 𝐘𝐎𝐔 𝐆𝐄𝐓】360° rotatable, caliper press tool that can be used in any direction, and it is more efficient and easier to handle than most brake caliper presses. Two large push plates that can apply force evenly. Two caliper hooks to protect the brake fluid lines and calipers. A comprehensive instruction manual.
  • 【𝐔𝐍𝐈𝐕𝐄𝐑𝐒𝐀𝐋 𝐁𝐑𝐀𝐊𝐄 𝐂𝐀𝐋𝐈𝐏𝐄𝐑 𝐏𝐈𝐒𝐓𝐎𝐍 𝐓𝐎𝐎𝐋】The brake caliper press tool is compatible from 1.5 inch to 2.75 inch. Thus, brake caliper compression tool can be compatible with 99% of twin and quad piston fixed calipers, as well as single and twin piston floating calipers. Admittedly, this tool can repair the brake pads of several cars, thus making the most of its value.
  • 【𝐄𝐀𝐒𝐘 𝐓𝐎 𝐔𝐒𝐄】The adjustment switch allows quick switching between expansion and compression modes. The operating handle allows the centrally located ratchet to spread the force evenly in a parallel manner. At the same time, the extended handle and double riveting make use of the process both easy and stable. The brake piston can be compressed effortlessly in seconds. TIPS: BEFORE EXPANSION, A RING OF FREE THREAD NEEDS TO BE LEFT TO HELP START.
  • 【𝐒𝐓𝐔𝐑𝐃𝐘 𝐀𝐍𝐃 𝐃𝐔𝐑𝐀𝐁𝐋𝐄】The thickened push plate is made of 45 gauge steel, which has excellent strength and toughness and is not easily deformed.The ratchet system and adjustment switch are also made of #45 steel, excellent strength and durability. The chrome-plated metal handle is overmolded for a comfortable grip, uniform force, and non-slip.
  • 【𝐖𝐎𝐑𝐓𝐇 𝐈𝐍𝐕𝐄𝐒𝐓𝐌𝐄𝐍𝐓】In addition to getting a high quality brake piston compressor tool set, you will also get an extremely detailed instruction manual. And this manual will teach you how to replace your brake pads. Learning this skill can save you a ton of money or even be used to make money. GallopMax --- strives to give more value to every choice you make! If you have problems, feel free to contact, we're always here!
Bestseller No. 9
Orion Motor Tech 24pcs Heavy Duty Disc Brake Piston Caliper Compressor Rewind Tool Set and Wind Back Tool Kit for Brake Pad Replacement Reset, Fits Most American, European, Japanese Autos
  • EASY OPERATION: For brake pad and shoe replacement and rotating pistons back into the caliper on your car, truck or 4-wheel drive disc brake vehicle. Includes both right-handed and left-handed thrust bolt assemblies.
  • UNIVERSAL COMPATIBILITY: This multi-disc brake caliper wind back tool kit includes 18 adapters fitting hundreds of vehicle makes and models including American, European, and Japanese. See the Product Description section below for a more complete list.
  • HEAVY-DUTY DURABILITY: Carbon steel construction with a rust-proof blasted finish, these components will stand up to heavy use and accidental drops. It’s perfect for everyone from DIY novices to professional mechanics.
  • CONVENIENT CARRY CASE: Includes an ABS carrying case with pre-sized slots for every component - right and left-handed thrust bolts, 2 retaining plates, and 18 disc adapters.
  • TECHNICAL SUPPORT: Each kit includes a detailed user manual with an illustrated parts diagram. We pursue outstanding quality and professional technical support. If you are not satisfied with this product or if you have any questions, please let us know.
Bestseller No. 10
JOJOY LUX Brake Caliper Press Tool, 360 Degree Swing Ratchet Expander Wrench Car Wheel Piston Spreader with Extra 2PCS Large Plates for Single Twin Quad Sextuplet Piston Disc Brake Caliper
  • 【Application】This brake caliper press tool suits for disc brake, NOT for drum brake. The tool is equipped with 2 groups of push boards: 7.01x2.36"and 4.53x2.17".Smaller ones are suitable for disc brake system with twin and quad pistons fixed calipers, or single and twin pistons floating calipers. The bigger ones more fit for some sextuplet pistons fixed calipers. Also this ratcheting caliper spreader is designed to "push" the piston back, can not twist and compress, which some brakes need.
  • 【Labor Saving】Brake repair brake spreading tool adopts 360 degree ratchet design, it is easy to get into place and use from any direction, also your hands will not get fatigued from the constant squeezing. The ratchet is in the centre of the dual piston brake caliper compressor, the two spreading plates keep parallel, make sure to spread the force on the caliper piston evenly, in case of caliper damage or pistons dislocation.
  • 【Use-friendly】 Swing the long lever handle to expand and retract the spreading plates, and the positive and negative regulation is realized by flipping the reversing switch in the ratchet. Because of ratcheting mechanism, both spreading plates need pressure to start the ratchet, please squeeze them for the first few swing until the suitable size to insert into the calipers, then go ahead to swing.
  • 【Premium Quality】Our brake caliper compressor uses high quality spreading plates with 1/8" thickness steel, high strength, not easy to deform. The lever handle has red cushion, skid resistance and feel good, will not hurt your hand while using. The bigger spreading plates with build-in small magnets and cylindrical pins, can install and unload quickly and easily from the compressor.
  • 【Buy with confidence】 We offer 2 yr hassle free warranty, any quality issues in the meantime, you can ask for replacement. If they do not work for your car, you can use 90 days money-back policy.

Last update on 2023-01-21 / Affiliate links / Images from Amazon Product Advertising API

This product was presentation was made with AAWP plugin.

Leave a Comment

Share to...