2004 Dodge Ram Truck 1500-2500-3500 Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Year: 2004 Model Variant: 1500, 2500, 3500 👋 Introduction Market Position Segment: Full-size Pickup Truck Key Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra Key Features Platform: Third Generation Dodge Ram (DR platform) Design Philosophy: Robust construction, powerful engine options, distinctive 'big rig' styling. Manual Value Proposition: Empowers owners and independent repair shops with dealership-level diagnostic and repair information. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Page Count Estimated Page Count: 1500-2000+ (Typical for comprehensive factory service manuals of this era) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (Instant Download - likely PDF) 📖 Manual Coverage Systems Covered Engine: Diagnosis, repair, and overhaul of all engines offered for 2004 Ram (e.g., 5.7L HEMI, 4.7L Magnum, 3.7L Magnum, 5.9L Cummins Diesel) Transmission: Service and repair procedures for automatic (e.g., 48RE, 545RFE) and manual transmissions, including clutch system, torque converter, and transfer case (4x4 models) Drivetrain: Front and rear axle service, differential repair, driveshaft, U-joints, and CV joints. Suspension: Front and rear suspension components, steering system, alignment specifications, shock absorbers, springs, control arms. Brakes: Front and rear brake systems (disc/drum configurations), ABS operation and diagnosis, parking brake, hydraulic components. Electrical: Complete wiring diagrams, component location, diagnostic procedures for lighting, ignition, charging system, starting system, body control modules (BCM), Powertrain Control Module (PCM), instrument cluster, and accessories. HVAC: Air conditioning system diagnosis and repair, heater core, blower motor, climate controls. Body: Exterior body panel repair, door mechanisms, interior trim, glass replacement, bumpers, hood, tailgate. Fuel System: Fuel pump, injectors, fuel filter replacement, fuel tank service, emissions control systems. Exhaust: Exhaust system components, catalytic converter, muffler, oxygen sensors. Procedures Included Maintenance: Oil change, filter replacement, fluid checks and changes, tire rotation, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common fault code explanations. Repair: Step-by-step repair instructions for all major vehicle systems, including component removal and installation, torquing specifications, and assembly. Diagnostics: On-Board Diagnostics (OBD-II) system explanation, diagnostic trouble code (DTC) interpretation, and component testing procedures. Overhaul: Detailed procedures for engine and transmission overhauls, including component measurements and clearances. Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to complex engine and transmission rebuilds and advanced electrical diagnostics. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Quality: High-resolution, typically scan quality equivalent to original factory manuals, ensuring clarity of diagrams and text. Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine 2004 Engine Options: 3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 5.9L Cummins Turbo Diesel I6 Performance 5.7L Hemi Horsepower: Approx. 345 hp @ 5200 rpm 5.7L Hemi Torque: Approx. 375 lb-ft @ 4000 rpm 5.9L Cummins Torque: Approx. 555 lb-ft @ 1400 rpm (for standard output models) Fuel System Fuel Injection Type: Multi-point Fuel Injection (MPI) for gasoline engines, High-pressure Common Rail (HPCR) for Cummins diesel Engine Codes Engine Code Examples: 2004 Ram 1500 5.7L V8 (HEMI) = EZH; 2004 Ram 2500/3500 5.9L Cummins = ETH 🔧 Transmission Standard Common Automatic: 48RE (4-speed automatic, typically with V8 and diesel engines) Optional Other Automatic: 545RFE (5-speed automatic, typically with 4.7L V8) Manual Transmission: NV5600 (6-speed manual, common with 5.9L Cummins diesel) Features Transfer Case: Electronic Shift-on-the-Fly (ESOF) or manual transfer case for 4WD models Fluid Specifications 48Re Fluid Type: ATF+4 (Chrysler Mopar) Nv5600 Fluid Type: SYNCHROMESH (GL-3/GL-4 specification) 📐 Dimensions Exterior Wheelbase Options: Various (e.g., 130.5" for Quad Cab short bed, 140.5" for Quad Cab long bed, 160.5" for Regular Cab long bed) Bed Length Options: 6.3 ft (short bed), 8.0 ft (long bed) Weights Gvwr Range: Approx. 8,510 lbs (1500) to 12,000+ lbs (3500) Curb Weight Range: Approx. 5,000 lbs to 7,000+ lbs depending on configuration 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Typically 3 or 4 stars depending on configuration and drive type. Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Available Systems: Factory AM/FM stereo with CD player, optional premium audio systems, and early navigation systems on higher trims. Driver Assistance Availability: Limited by modern standards; primarily focused on passive safety and standard ABS. Connectivity Features: Optional SiriusXM Satellite Radio, power accessories (windows, locks). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-7,500 miles depending on engine and driving conditions (refer to manual for specific recommendations). Transmission Fluid Change: Around 30,000-100,000 miles for automatic transmissions, depending on severe/normal use (refer to manual). Fluid Specifications Engine Oil 5.7L Hemi: SAE 5W-20 (or 5W-30 depending on temperature range), API Certified Engine Oil 5.9L Cummins: API CJ-4 or CK-4 rated diesel engine oil, 15W-40 (check manual for specific viscosity grade based...
Empowers owners and independent repair shops with dealership-level diagnostic and repair information.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Page Count
Estimated Page Count:
1500-2000+ (Typical for comprehensive factory service manuals of this era)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (Instant Download - likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Diagnosis, repair, and overhaul of all engines offered for 2004 Ram (e.g., 5.7L HEMI, 4.7L Magnum, 3.7L Magnum, 5.9L Cummins Diesel)
Transmission:
Service and repair procedures for automatic (e.g., 48RE, 545RFE) and manual transmissions, including clutch system, torque converter, and transfer case (4x4 models)
Drivetrain:
Front and rear axle service, differential repair, driveshaft, U-joints, and CV joints.
Suspension:
Front and rear suspension components, steering system, alignment specifications, shock absorbers, springs, control arms.
Brakes:
Front and rear brake systems (disc/drum configurations), ABS operation and diagnosis, parking brake, hydraulic components.
Electrical:
Complete wiring diagrams, component location, diagnostic procedures for lighting, ignition, charging system, starting system, body control modules (BCM), Powertrain Control Module (PCM), instrument cluster, and accessories.
HVAC:
Air conditioning system diagnosis and repair, heater core, blower motor, climate controls.
Body:
Exterior body panel repair, door mechanisms, interior trim, glass replacement, bumpers, hood, tailgate.
Fuel System:
Fuel pump, injectors, fuel filter replacement, fuel tank service, emissions control systems.
Exhaust:
Exhaust system components, catalytic converter, muffler, oxygen sensors.
Procedures Included
Maintenance:
Oil change, filter replacement, fluid checks and changes, tire rotation, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common fault code explanations.
Repair:
Step-by-step repair instructions for all major vehicle systems, including component removal and installation, torquing specifications, and assembly.
Diagnostics:
On-Board Diagnostics (OBD-II) system explanation, diagnostic trouble code (DTC) interpretation, and component testing procedures.
Overhaul:
Detailed procedures for engine and transmission overhauls, including component measurements and clearances.
Technical Depth
Depth:
Comprehensive, covering everything from basic routine maintenance to complex engine and transmission rebuilds and advanced electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Quality:
High-resolution, typically scan quality equivalent to original factory manuals, ensuring clarity of diagrams and text.
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
2004 Engine Options:
3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 5.9L Cummins Turbo Diesel I6
Performance
5.7L Hemi Horsepower:
Approx. 345 hp @ 5200 rpm
5.7L Hemi Torque:
Approx. 375 lb-ft @ 4000 rpm
5.9L Cummins Torque:
Approx. 555 lb-ft @ 1400 rpm (for standard output models)
Fuel System
Fuel Injection Type:
Multi-point Fuel Injection (MPI) for gasoline engines, High-pressure Common Rail (HPCR) for Cummins diesel
48RE (4-speed automatic, typically with V8 and diesel engines)
Optional
Other Automatic:
545RFE (5-speed automatic, typically with 4.7L V8)
Manual Transmission:
NV5600 (6-speed manual, common with 5.9L Cummins diesel)
Features
Transfer Case:
Electronic Shift-on-the-Fly (ESOF) or manual transfer case for 4WD models
Fluid Specifications
48Re Fluid Type:
ATF+4 (Chrysler Mopar)
Nv5600 Fluid Type:
SYNCHROMESH (GL-3/GL-4 specification)
📐 Dimensions
Exterior
Wheelbase Options:
Various (e.g., 130.5" for Quad Cab short bed, 140.5" for Quad Cab long bed, 160.5" for Regular Cab long bed)
Bed Length Options:
6.3 ft (short bed), 8.0 ft (long bed)
Weights
Gvwr Range:
Approx. 8,510 lbs (1500) to 12,000+ lbs (3500)
Curb Weight Range:
Approx. 5,000 lbs to 7,000+ lbs depending on configuration
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
Typically 3 or 4 stars depending on configuration and drive type.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Available Systems:
Factory AM/FM stereo with CD player, optional premium audio systems, and early navigation systems on higher trims.
Driver Assistance
Availability:
Limited by modern standards; primarily focused on passive safety and standard ABS.
Connectivity
Features:
Optional SiriusXM Satellite Radio, power accessories (windows, locks).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles depending on engine and driving conditions (refer to manual for specific recommendations).
Transmission Fluid Change:
Around 30,000-100,000 miles for automatic transmissions, depending on severe/normal use (refer to manual).
Fluid Specifications
Engine Oil 5.7L Hemi:
SAE 5W-20 (or 5W-30 depending on temperature range), API Certified
Engine Oil 5.9L Cummins:
API CJ-4 or CK-4 rated diesel engine oil, 15W-40 (check manual for specific viscosity grade based on temperature)
Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) 50/50 mix with distilled water.
Known Issues
Common Problem 1:
Valve spring issues in early 5.7L HEMI engines (TSBs often addressed this).
Common Problem 2:
Fuel pump failure, especially in extreme heat or with poor fuel quality.
Common Problem 3:
Transmission cooler line leaks in automatic transmissions.
Common Problem 4:
Death wobble (steering/suspension instability) in some 4WD models, often related to worn components.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks, with the Ram nameplate being a cornerstone since 1981.
Model Evolution
Third Generation:
The 2004 model year falls within the third generation (2002-2008) of the Dodge Ram, characterized by its significant redesign and introduction of the HEMI engine.
Production
Manufacturing Location:
Warren Truck Assembly Plant, Warren, Michigan
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The 5.7L HEMI engine was widely praised for its power and responsiveness, contributing to the Ram's strong market presence.
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