Brake Line Routing Fluid Leak – 2020 Ram 4500 & 5500

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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

For the Latest and Most Recent Recalls Information Visit the link below…

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

 


 

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Last update on 2024-02-21 / Affiliate links / Images from Amazon Product Advertising API

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