22E086 – ZA6 – Incorrect Brake Hose Diameter – Mopar Brake Hoses

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October 11, 2022 NHTSA CAMPAIGN NUMBER: 22E086000

Incorrect Brake Hose Diameter/FMVSS 106

A brake hose rupture can cause a loss of braking ability, increasing the risk of a crash.

 

NHTSA Campaign Number: 22E086

Manufacturer Chrysler (FCA US, LLC)

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 183

 

Summary

Chrysler (FCA US, LLC) is recalling certain Mopar right rear brake hoses with part numbers 68371722AA and 68371722AB, and left rear brake hoses with part number 68371723AB. The brake hose inside diameter may be too small, which could cause the hose to rupture. As such, these hoses fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 106, “Brake Hoses.”

 

Remedy

Dealers will replace the hose, free of charge. If the hose is not installed on a vehicle, dealers will inspect the production date label and replace the hose as necessary, free of charge. Owner notification letters were mailed April 27, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is ZA6.

 

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.nhtsa.gov.

 


New Safety Recall Advanced Communication – ZA6

FCA US LLC (FCA US) has announced an equipment safety recall on certain Mopar aftermarket rear brake hoses, right rear 68371722AA, right rear 68371722AB, and left rear 68371723AB, intended for use on 2019 and 2020 Model Year (DP) Ram 4500/5500 Cab Chassis vehicles.

 

REASON FOR THIS SAFETY RECALL

Some of the above rear brake hoses manufactured and sold as aftermarket equipment may have been manufactured with an orifice diameter that is not within specification. A brake hose that does not meet constriction requirements may be more susceptible to hose assembly rupture. A ruptured brake hose could result in reduced braking performance, which may increase the risk of a crash without prior warning.

The condition described above does not comply with Federal Motor Vehicle Safety Standard (FMVSS) No. 106 S5.3.1 Constriction requirement states: “Except for that part of an end fitting which does not contain hose, every inside diameter of any section of a hydraulic brake hose assembly shall be not less than 64 percent of the nominal inside diameter of the brake hose.” Brake hoses that have an out of specification orifice diameter have an inside diameter that is less than the 64 percent requirement.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on rear brake hoses. If installed on a vehicle, FCA US will remove the affected hose and install a new hose. If not installed on a vehicle, FCA US will inspect the production date label to determine if the hose is affected and replace if needed. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 4th Quarter of 2022.

 


April 2023

Dealer Service Instructions for:

Equipment Safety Recall
ZA6 / NHTSA 22E-086
Rear Brake Hose

 

Remedy Available  

Mopar Right rear brake hose 68371722AA
Mopar Right rear brake hose 68371722AB
Mopar Left rear brake hose 68371723AB

 

Intended for use with 2019 and 2020 Model Year (DP) Ram 4500/5500 Cab Chassis vehicles.

 

Subject

Some of the above rear brake hoses sold as aftermarket equipment may have an orifice diameter that is not within specification. A brake hose that does not meet constriction requirements may be more susceptible to hose assembly rupture. A ruptured brake hose could result in reduced braking performance, which may increase the risk of a crash without prior warning.

The condition described above does not comply with Federal Motor Vehicle Safety Standard (FMVSS) No. 106 S5.3.1 Constriction requirement states: “Except for that part of an end fitting which does not contain hose, every inside diameter of any section of a hydraulic brake hose assembly shall be not less than 64 percent of the nominal inside diameter of the brake hose.” Brake hoses that have an out of specification orifice diameter have an inside diameter that is less than the 64 percent requirement.

 

Repair

If the brake hose/tube assembly has not been installed, refer to the following Exchange Procedure on Page 3.

If the brake hose/tube assembly has been installed, replace it using the following Service Procedure on Page 5.

 

Parts Information

NOTE: Order only the Hose/Tube Assembly that is required.

NOTE: Hose/Tube Assembly includes banjo bolt, washers, and retainers.

Part Number Qty. Description
68371722AB 1 Brake Hose/Tube Assembly, Right Rear
68371723AB 1 Brake Hose/Tube Assembly, Left Rear
04318080AD 1 Brake fluid DOT 3 12oz. bottle (MS-4574)

 

Parts Return

No parts return required for this campaign.

Render the recalled brake hose/tube assembly unusable and discard.

 

Special Tools

The following special tools are required to perform this repair:

➢ NPN Brake Bleeding Equipment
➢ NPN Brake Holding Tool

 

Exchange Procedure

Use this procedure for any uninstalled brake hose.

 

  1. Locate the Julian Data Code stamped on the hose coupler (Figure 1).

 

  1. Read and record the Julian Data Code, a magnifying lens and a bright light may be necessary to view the date code.

 

  1. For deciphering the Julian Data Code refer to (Figure 2). The dates of suspect parts are as follows:
  • P/N ending in 22AA – 1/29/2019 thru 3/21/2020
  • P/N ending in 22AB – 6/9/2020 thru 8/20/2020
  • P/N ending in 23AB – 4/1/2020 thru 8/19/2020
HCO Y M DD X NNNNNN

Last 6 Characters of Part Number

Production Shift 1, 2, 3

Day of Month

Month: 1-9 (Jan – Sept) X, Y, Z (Oct, Nov, Dec)

Manufacture Date Last Digit of the Year (9 = 2019) (0 = 2020) etc.    

 

  1. Is the brake hose one of the suspect parts based on the Julian Date Code?
  • YES: Julian Date Code identifies brake hose was produced during the suspect production dates. Exchange the brake hose for a new brake hose.
  • NO: Julian Date Code identifies brake hose was NOT produced during the suspect production dates. Return the brake hose to the customer.

 

Service Procedure

A. Brake Hose/Tube Assembly Removal

 

  1. Using a brake pedal holding tool, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake hoses/tubes are being serviced (Figure 3).

 

  1. Raise and support the vehicle.

 

  1. If equipped; release the Antilock Brake System (ABS) wire retainers from the rear brake fluid tube (Figure 4).

 

  1. Remove and SAVE the bolt securing the brake hose/tube support bracket to the rear axle (Figure 5).

 

  1. Remove the brake hose/tube plastic retainer from the rear axle (Figure 5).

 

  1. Place a suitable drain pan under the brake hose/tube connections to capture lost fluid while disconnecting.

 

  1. Remove the banjo bolt with copper washers and brake hose from the rear brake caliper (Figure 6).

 

  1. Disconnect the brake tube from the junction block above the rear axle differential (Figure 7).

 

  1. Render the brake hose/tube assembly unusable and DISCARD.

 

B. Brake Hose/Tube Assembly Installation

  1. Position the NEW brake hose/tube assembly to the rear axle.

 

  1. Connect the brake tube to the junction block above the rear axle differential. Tighten the brake tube flare nut to 20 N·m (15 Ft. Lbs.) (Figure 7).

 

  1. Install the brake hose to the rear brake caliper. NEW banjo bolt and copper washers are included as part of the brake hose assembly. Tighten the banjo bolt to 35 N·m (26 Ft. Lbs.) (Figure 6).

 

  1. Secure the brake hose/tube plastic retainer to the rear axle (Figure 5).

 

  1. Install the bolt securing the brake hose/tube support bracket to the rear axle. Tighten the bolt to 16 N·m (12 Ft. Lbs.) (Figure 5).

 

  1. If equipped; attach the ABS wire retainers to the rear brake fluid tube (Figure 4).

 

  1. Remove the brake pedal holding tool (Figure 3).

 

  1. Partly lower the vehicle and open the hood.

 

NOTE: Use Mopar® brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use ONLY fresh, clean fluid from a sealed container.

 

  1. Remove reservoir filler cap and fill reservoir.

 

  1. Top off the brake fluid if necessary.

 

  1. Attach one end of the bleed hose (1) to the bleed screw and insert the opposite end into a glass container (2) partially filled with brake fluid. Be sure the end of the bleed hose is immersed in fluid (Figure 8).

 

NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear. Bleeding of the front calipers will not be necessary.

 

  1. MANUAL BLEEDING

a. Open the bleeder, then have a helper press down the brake pedal. Once the pedal is down, hold the pedal down while closing the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel.

b. Apply brake pressure several times to seat the brake pads and obtain a firm brake pedal.

c. Tighten the caliper bleed screws to 10 N·m (89 In. Lbs.).

 

  1. PRESSURE BLEEDING

NOTE: Follow the manufacturer’s instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is adequate for bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system.

 

a. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding.

b. Open the bleeder until fluid stream is clear and free of bubbles. Then move to the next wheel.

c. Tighten the caliper bleed screws to 10 N·m (89 In. Lbs.).

 

  1. Top off the brake fluid and install the reservoir cap.

 

  1. Clean any excess brake fluid from vehicle.

 

  1. Close the hood.

 

  1. Lower the vehicle.

 

  1. Return the vehicle to the customer or inventory

 

Owner Notification and Service Scheduling

All involved vehicle owners known to FCA are being notified of the service requirement by first class mail.  They are requested to schedule appointments for this service with their dealers.  A generic copy of the owner letter is attached.

 

RCRIT-22E086-6511

 


Chronology :

  • On August 28, 2020, the FCA US LLC (“FCA US”) Vehicle Safety and Regulatory Compliance (“VSRC”) organization opened an investigation based on information from the FCA US Chassis Engineering group of a potential noncompliance for the rear brake hose assembly on 2019 and 2020 MY Ram 4500/5500 cab chassis vehicles.
  • On September 23, 2020, the FCA US VSRC organization confirmed that rear brake hose assemblies may have been built with an orifice diameter that is out of specification.
  • On October 15, 2020, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected units.
  • On October 22, 2020, FCA US filed a Noncompliance Information Report pursuant to 49 CFR Part 573 which was assigned NHTSA recall number 20E-080 and FCA US Recall Number W76.
  • On November 13, 2020, FCA US petitioned the NHTSA, pursuant to 49 CFR Part 556, for exemption from the notification and remedy requirements.
  • On October 5, 2022, FCA US received notice that the NHTSA denied FCA US’ petition.

 


2 Affected Products

Equipments

BRAND PART NO. PRODUCTION DATES
MOPAR LEFT REAR BRAKE HOSE
MOPAR RIGHT REAR BRAKE HOSE

 


10 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-22E086-3303.PDF 216.365KB

RCLRPT-22E086-3303

 


Manufacturer Notices(to Dealers,etc) – Dealer Notification re New Safety Recall Advanced Communication – ZA6

RCMN-22E086-2327.pdf 97.51KB

RCMN-22E086-2327

 


Recall Acknowledgement

RCAK-22E086-8127.pdf 645.256KB

RCAK-22E086-8127

 


Manufacturer Notices(to Dealers,etc) – NSRAC Owner Interim Combo

RCMN-22E086-5727.pdf 227.136KB

RCMN-22E086-5727

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22E086-9280.pdf 148.225KB

RIONL-22E086-9280

 


Recall 573 Report – 12/13/22

RCLRPT-22E086-4015.PDF 216.418KB

RCLRPT-22E086-4015

 


Remedy Instructions and TSB

RCRIT-22E086-6511.pdf 1356.194KB

RCRIT-22E086-6511

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22E086-1713.pdf 148.344KB

RCONL-22E086-1713

 


Recall Quarterly Report #1, 2023-2

RCLQRT-22E086-2178.PDF 211.136KB

RCLQRT-22E086-2178

 


Recall Quarterly Report #2, 2023-3

RCLQRT-22E086-2066.PDF 211.373KB

RCLQRT-22E086-2066

 


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=22E086&docType=RCL

 


 

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Last update on 2024-02-15 / Affiliate links / Images from Amazon Product Advertising API

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