RAM 1500 Brake Release Fix

thingiverse

I have a 2012 RAM 1500. My parking brake release handle broke the other day. (Apparently, this is a common problem, but it’s the first time it’s happened to me in 8 years.) I looked around at forums to see if there was any DIY fixes for it. There were none except to buy a replacement part for about $30US plus shipping. (https://autopartscheaper.com/products/2009-2012-dodge-ram-1500-parking-brake-release-handle-genuine-new-1nl97dk2ab) I took a closer look at the part and noticed the stamp on the back said ABS. This is good news as ABS is pretty easy to glue; much better than PP or AE. I also noticed that there were come hollowed out parts in the mold where the hinge parts are. I decided to use this to my advantage. I created these supports to insert into these hollowed out areas and then used Methyl Ethyl Ketone (MEK). I live in Canada and found it at Canadian Tire. I’m sure it’s available in other parts of the world. (https://www.canadiantire.ca/en/pdp/solvable-methyl-ethyl-ketone-mek-946-ml-0475884p.html) Notice that there are two models here. It’s because the two hinge parts are different widths. Make dry fits before putting the MEK solvent on it to make sure you have the parts oriented and aligned properly. Once you know how it all goes together, apply the solvent to the three sides of the channel and press the part in. I just used a cotton swab to apply the MEK. I recommend doing each hinge all at once so you can get it all lined up properly in one go. Once they are together, it’s a mechanical bond so separation of the parts is impossible without distorting or breaking something. I have attached pictures of the various stages of the fix. Note that this fix is only for if one or both of the hinge parts are broken. This doesn’t fix the problem if the rod mount has broken off from the handle part. It would be best to print this in ABS as that will allow for the mechanical bond with MEK as both parts are the same material. I have not tried this in PLA or PETG so don’t ask. ;-) This may fit other years of RAM 1500, 2500, etc but I don’t really know. If you have success, please comment here with the make and model of the vehicle so I can add it to the list at the bottom. If you cannot print these models, or cannot print ABS, send me a message here and maybe we can work something out. The parts are small, so they can be mailed out to you pretty easily. There are lots of videos on YouTube about how to remove and replace the handle. Here’s an example: https://www.youtube.com/watch?v=Lgu5uVAI65E Successful models tested on: 2012 RAM 1500 Laramie