ZA5 – Incorrect Brake Hose Diameter – 2019-2020 Ram 4500 & 5500 Cab Chassis

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October 11, 2022 NHTSA CAMPAIGN NUMBER: 22V759000

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: 22V759

Manufacturer Chrysler (FCA US, LLC)

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 26,961

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2019-2020 Ram 4500 and 5500 Cab Chassis vehicles. The rear brake hose inside diameter may be too small, which could cause the hose to rupture. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 106, “Brake Hoses.”

 

Remedy

Dealers will replace the rear brake hoses, 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 ZA5.

 

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.

 

Check if your Vehicle has a Recall

 


New Safety Recall Advanced Communication – ZA5

FCA US LLC (FCA US) has announced a safety recall on certain 2019 and 2020 Model Year (DP) Ram 4500/5500 Cab Chassis vehicles.

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have a rear brake hose with an out of specification orifice diameter. 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 to replace the rear brake hoses. 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:

Safety Recall ZA5 / NHTSA 22V-759 Rear Brake Hose

 

Remedy Available

2019-2020 (DP) Ram 4500/5500 Cab Chassis

 

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement toapply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The rear brake caliper hose on about 26,960 of the above vehicles 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

Replace both brake hose/tube assemblies

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

 

Parts Information

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

Part Number Qty. Description
CSCLZA51AA 1 Brake Hose/Tube Assembly, Right and 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

 

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 1).

 

  1. Raise and support the vehicle.

 

  1. If equipped; release the Antilock Brake System (ABS) wire retainers from the rear brake fluid tube (Figure 2).

 

  1. Remove and SAVE the bolt securing the brake hose/tube support bracket to the rear axle (Figure 3).

 

  1. Remove the brake hose/tube plastic retainer from the rear axle (Figure 3).

 

  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 4).

 

 

  1. Disconnect the brake tube from the junction block above the rear axle differential (Figure 5).

 

  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 5).

 

  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 4).

 

  1. Secure the brake hose/tube plastic retainer to the rear axle (Figure 3).

 

  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 3).

 

  1. If equipped; attach the ABS wire retainers to the rear brake fluid tube (Figure 2).

 

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

 

  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 6).

 

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

 


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 vehicles.
  • On October 22, 2020, FCA US filed a Noncompliance Information Report pursuant to 49 CFR Part 573 which was assigned NHTSA recall number 20V-649 and FCA US Recall Number W75.
  • 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.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
RAM 4500 2019-2020
RAM 5500 2019-2020

 


14 Associated Documents

Manufacturer Notices(to Dealers,etc) – Dealer Notification re New Safety Recall Advanced Communication – ZA5

RCMN-22V759-7263.pdf 48.502KB

RCMN-22V759-7263

 


Noncompliance Notice 573 Report

RCLRPT-22V759-4640.PDF 214.388KB

RCLRPT-22V759-4640

 


Recall Acknowledgement

RCAK-22V759-5600.pdf 645.162KB

RCAK-22V759-5600

 


Manufacturer Notices(to Dealers,etc) – NSRAC Final

RCMN-22V759-7875.pdf 51.871KB

RCMN-22V759-7875

 


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

RCMN-22V759-5638.pdf 103.301KB

RCMN-22V759-5638

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V759-1507.pdf 67.171KB

RIONL-22V759-1507

 


Recall 573 Report – 12/13/22

RCLRPT-22V759-9101.PDF 214.429KB

RCLRPT-22V759-9101

 


Remedy Instructions and TSB

RCRIT-22V759-5267.pdf 1246.922KB

RCRIT-22V759-5267

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V759-8649.pdf 174.656KB

RCONL-22V759-8649

 


Miscellaneous Document – Email Blast re Details of the Recall

RMISC-22V759-3807.pdf 166.707KB

RMISC-22V759-3807

 


Miscellaneous Document

RMISC-22V759-0958.pdf 501.067KB

RMISC-22V759-0958

 


Recall 573 Report – 12/13/22

RCLRPT-22V759-1218.PDF 214.429KB

RCLRPT-22V759-1218

 


Recall Quarterly Report #1, 2023-2

RCLQRT-22V759-3511.PDF 211.149KB

RCLQRT-22V759-3511

 


ISSUED Renotification Notice

RCRN-22V759-4825.pdf 146.272KB

RCRN-22V759-4825

 


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=22V759&docType=RCL

 


 

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

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