2019-2020 Ram 4500/5500 Brake Line Modification & Replacement – LiquidSpring – Compressible Liquid Adaptive Suspension Systems

May 13, 2020 NHTSA CAMPAIGN NUMBER: 20E031000

Brake Line Routing May Cause Wear and 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: 20E031

Manufacturer LiquidSpring LLC

Components SUSPENSION, SERVICE BRAKES, HYDRAULIC, SERVICE BRAKES

Potential Number of Units Affected 397

 

Summary

LiquidSpring LLC (LiquidSpring) is recalling certain Compressible Liquid Adaptive Suspension Systems (C.L.A.S.S.), part numbers DS135RS3A, DS135RS3AF, DS135RS3-DM, sold for use with 2019-2020 RAM 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. As such, these parts fail to comply with Federal Motor Vehicle Safety Standard (FMVSS) number 105, “Hydraulic and Electric Brake Systems.”

 

Remedy

LiquidSpring has notified the purchasers, and the affected vehicle manufacturers will file recalls to have their dealers inspect the rear brake caliper flexible lines for wear and install a kit to modify the rear brake caliper flexible line mounting, and if necessary, a kit to replace worn brake lines, free of charge. The recall May 13, 2020. Owners may contact LiquidSpring customer service at 1-765-474-7816, extension 1.

 

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.

 

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LiquidSpring® LLC
4899 E 400 S, LAFAYETTE, IN 47905
PH: 765-474-7816, FAX: 765-474-7826
www.liquidspring.com

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.

 

Figure 1:  Area to inspect for wear on flexible brake line encircled

 

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.

 

Figure 2:  Supplied Banjo Blocks, Bolts, and Crush Washers

Figure 3:  Banjo Bolt & Washers to Remove 

 

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

Note: Prop up brake line to minimize fluid loss.

4. 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.

 

Figure 4: Installation of Relocation Block

5. 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
6. Torque banjo bolt to 25 ft-lbs.

 

Figure 5: Installation of Driver Side OEM Brake Line to Relocation Block

7. Follow steps 2-4 for the RH side.
8. 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
9. Torque banjo bolt to 25 ft-lbs.

 

Figure 6: Installation of Passenger Side OEM Brake Line to Relocation Block

 

10. 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.

 

Figure 7: An example of pressure bleed system: Mityvac MV6840

 

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
Rev A

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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.)
3. Locate and remove the OE brake hose identified as being worn. Discard brake hose and crush washers. Retain banjo bolt.

 

Figure 1:  Banjo Bolt & Washers to Remove

 

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

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

 

Figure 2: Installation of Relocation Block

8. 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
9. Torque banjo bolt to 25 ft-lbs.

 

Figure 3: Installation of Driver Side OEM Brake Line to Relocation Block

10. Follow steps 3-6 for the RH side.
11. 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
12. Torque banjo bolt to 25 ft-lbs.

 

Figure 4: Installation of Passenger Side OEM Brake Line to Relocation Block

 

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

 

Figure 5: Lower Axle Clamp Installation

 

14. Place the LH Axle Cradle under the axle and loosely attach to the Axle Seat using the 5/8” hardware.
15. Slip the 3/4” U-bolts into position. Lightly tighten u-bolts.  Repeat installation for RH side.
16. 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.

 

17. Torque 5/8” fastener to 172-210 ftlbs.
18. 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.

 

Figure 6: Installed Spiral wrap

 

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

 

Figure 7: Re-attach lower control arm

 

22. 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.

 

Figure 8: Adjust frame or axle to ride height when tightening control arm fasteners

 

23. Torque 1” Fasteners to 600 ft-lbs, Dry.
24. Reinstall 80A fuse and reconnect power to the LiquidSpring system.
25. 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.

 

Figure 9: An example of pressure bleed system: Mityvac MV6840

 

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

 

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Important Safety Recall

NHTSA Recall Number: 20E031

 

Date: May 13, 2020

Subject: RAM Rear Brake Caliper Flexible Line Modification Safety Recall Notice

 

Dear LiquidSpring Suspension Owner,

This notice is being sent to you in accordance with the requirements of the National Highway Traffic and Motor Vehicle Safety Act.

 

LiquidSpring LLC has determined that a defect which relates to motor vehicle safety exists in a component of certain LS suspension systems installed on 2019-20 model year RAM 4500/5500 cab chassis, and only suspension systems installed on the above chassis are included in the safety recall.

 

These suspension systems are typically installed on ambulances and other specialty vehicles. The affected system component is the rear brake caliper flexible line. The routing of the rear brake caliper flexible lines during the installation of the suspension kit may be causing brake caliper flexible line wear due to contact with a suspension component(s). Continued vehicle use with the rear brake caliper flexible line contacting suspension a component(s) may result in partial or complete loss of rear service brakes which could cause damage to the chassis and/or other vehicles, and possibly result in a crash.

 

You are receiving this notice because records indicate that you may have purchased a vehicle equipped with an affected LS suspension system. LiquidSpring recommends that vehicle operator(s) be aware of any abnormal brake pedal feedback or reduced braking ability and that the rear brake caliper flexible lines should be inspected for any leakage. If any wear is found on the rear brake caliper flexible lines (not the protective spiral wrap), do not drive the vehicle.

 

The affected suspension systems have a serial number range 2007563 – 2013191. The suspension system serial number may be found on the serial number plate located on the driver side front frame hanger of the suspension. See Figures 2 & 3 for the location and view of the serial number plate.

 

Figure 2. Serial Plate Location

Figure 3. Serial Plate

 

If you have a 2019-20 model year RAM 4500/5500 cab chassis equipped with a LiquidSpring suspension system within the above serial number range, please contact LiquidSpring to arrange service to have the rear brake caliper flexible lines inspected and modified to address the potential wear issue, free of charge. This repair will take about 1 hour to complete.

 

The LiquidSpring contact information is as follows:

Phone: 765-474-7816   Ext. 1 for Customer Service – 8:00 a.m. – 5:00 p.m. EDT Email: service@liquidspring.com

 

If LiquidSpring fails or is unable to arrange service as described above without charge, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, S.E., Washington, DC 20590 or call toll-free Auto Safety Hotline at 1-888327-4236 (TTY 1-800-424-9153); or go to www.safercar.gov.

 

Commitment to safety, quality and respect for the customer are our highest priorities. Please accept our sincere apology for any inconveniences that may result from modifying the rear brake caliper flexible lines.

 

Sincerely,

Dean F. Bartolone – President/CEO

 

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May 13, 2020

 

Manufacturer/Dealer Address

 

Subject: RAM Rear Brake Caliper Flexible Line Modification Safety Recall Notice

Dear Manufacturer/Dealer:

Attached please find a Safety Recall Notice #20X-XXX in which LiquidSpring needs to your assistance. While we have records of Manufacturer/Dealer Purchase Orders for installers and suspension serial numbers, we do not have records of dealers/end users of vehicles equipped with suspension systems affected by the Safety Recall Notice.

We have separately attached a list of your Purchase Orders and corresponding suspension kit serial numbers of affected suspension systems and we need you to provide us the dealer and/or end user contact information of the vehicles equipped with the affected suspension systems. If you purchased conversion kit, P/N 11685, to convert a 2018 MY suspension kit to 2019+ MY suspension kit, we have included a listing of 2018 MY suspension kits (DS135RS2A & DS135RS2AF) such that you can provide us the 2018 MY suspension kit serial number in which the conversion kit was applied along with the corresponding dealer and/or end user contact information of the vehicles equipped with the affected suspension systems.

LiquidSpring will contact the dealer to obtain end user contact information if this is not initially provided. We will mail the Safety Recall Notice to all affected dealers or end users depending on the possession of the vehicle.

Once the dealer or end user contacts us and verifies their vehicle is in the affected group, we will make arrangements with them to locate a local service center and cover labor and material costs to have the rear brake caliper flexible line inspection and modification performed. Please see the separately attached RAM 4500/5500 Brake Line Modification Instructions, D11848, for the remedy.

Commitment to safety, quality and respect for the customer are our highest priorities. Please accept our sincere apology for any inconveniences that may result from modifying the rear brake caliper flexible lines.

Sincerely,

Dean F. Bartolone – President/CEO

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7 Affected Products

Equipments

BRAND	PART NO.	PRODUCTION DATES
LIQUID SPRING	DS135RS3-DM
LIQUID SPRING	DS135RS3A
LIQUID SPRING	DS135RS3AF

 

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Vehicles

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

 

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8 Associated Documents

Recall Acknowledgement

RCAK-20E031-5668.pdf 245.062KB

 

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Remedy Instructions and TSB

RCRIT-20E031-7023.pdf 586.139KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20E031-7975.pdf 129.465KB

 

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Non-Compliance 573 Report

RCLRPT-20E031-3744.PDF 220.112KB

 

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Remedy Instructions and TSB

RCRIT-20E031-9039.pdf 624.937KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20E031-7816.pdf 286.546KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20E031-9747.PDF 211.228KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20E031-4430.PDF 211.228KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20E031&docType=RCL

 

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Last update on 2025-04-18 / Affiliate links / Images from Amazon Product Advertising API

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