Step-by-step diagnostic procedures for identifying and resolving common and uncommon faults.
Repair And Replacement:
Detailed instructions for component removal, installation, and adjustment for all vehicle systems.
Overhaul:
Complete engine and transmission overhaul procedures with detailed component specifications.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all circuits, including power distribution, grounds, and component connections.
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data.
Technical Depth
Depth:
Expert-level, suitable for professional technicians and advanced DIYers. Covers everything from basic fluid changes to complete engine and transmission rebuilds, as well as in-depth electrical diagnostics.
📊 Manual Specifications
File Format
Digital Format:
Typically PDF or a proprietary executable program with searchable content and interactive diagrams.
Print Quality
Printability:
High-resolution content suitable for printing individual sections or the entire manual.
All automatic transmissions and the NV4500 manual feature an overdrive gear for improved fuel economy at highway speeds.
Transfer Case:
NV271 (Manual Shift) or NV273 (Electronic Shift-on-the-Fly) for 4x4 models.
📐 Dimensions
Exterior
Wheelbase Regular Cab:
134.1 inches
Wheelbase Extended Cab:
140.5 inches
Wheelbase Crew Cab:
160.5 inches
Bed Length Standard:
6.3 feet (75.9 inches)
Bed Length Long:
8.0 feet (96.3 inches)
Weights
Gvwr Gas:
Up to 9,750 lbs
Gvwr Diesel:
Up to 10,000 lbs
Curb Weight:
Varies by configuration, typically 6,000 - 7,500 lbs.
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Rating:
4 out of 5 stars (for 4x2 models), 3 out of 5 stars (for 4x4 models) - Note: Ratings can vary slightly by specific configuration and test year.
Active Features
ABS:
Standard 4-wheel Anti-lock Braking System (ABS).
Passive Features
Airbags:
Standard driver and passenger front airbags. Side airbags may be optional depending on trim.
Seatbelts:
Height-adjustable front seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Base AM/FM stereo with CD player and optional Infinity premium audio system. Cassette player was still available on some models.
Climate Control:
Manual or optional dual-zone automatic climate control.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Outlets:
12V auxiliary power outlets in the cabin.
🔧 Maintenance
Service Intervals
Oil Change Gas:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (consult manual for specific recommendation).
Oil Change Diesel:
Every 7,500 miles or 6 months (synthetic oil recommended for optimal performance and longevity).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed. Critical for diesel engine performance.
Fuel Filter Replacement Diesel:
Every 15,000-30,000 miles (depending on fuel quality and manufacturer recommendation).
Transmission Fluid Service:
Automatic: 30,000-60,000 miles. Manual: Inspect regularly, fluid change typically recommended at higher mileage (e.g., 100,000 miles) or if experiencing issues.
Fluid Specifications
Engine Oil 5 7L 8 0L:
API SG, SH, SJ, or SL certified SAE 5W-30 or 5W-40 (refer to manual for specific viscosity based on temperature).
Engine Oil 5 9L Cummins:
API CJ-4 or CK-4 certified SAE 15W-40 (synthetic 5W-40 recommended for cold weather).
Coolant:
Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically a 50/50 mix with distilled water. Extended life coolant may be used if compatible.
Transmission Fluid Automatic:
ATF+4 (Automatic Transmission Fluid Type 95)
Transmission Fluid Manual Nv4500:
GL-3 or GL-4 rated gear oil, typically SAE 75W-90 or 80W-90.
Power Steering Fluid:
Chrysler Type MS-5937 or equivalent.
Known Issues
Cummins Injectors:
Early 5.9L common rail models can experience injector issues, often related to fuel contamination or wear.
Transmission 48Re:
The 48RE can sometimes develop issues with the torque converter clutch or solenoid pack, particularly under heavy use.
Steering Components:
Ball joints, tie rod ends, and steering box can wear over time due to the weight and usage typical for a heavy-duty truck.
Rust:
Corrosion on body panels, frame, and exhaust system can be an issue in areas with road salt.
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long and storied history in the truck market, with the RAM nameplate becoming synonymous with capability and durability.
Model Evolution
Third Generation Ram:
The 2004 model year falls within the third generation of the Dodge Ram (1994-2001 and 2002-2008). This generation marked a significant redesign with a more aggressive, muscular styling and improved chassis dynamics.
Production
Manufacturing Plant:
Saltillo Truck Assembly Plant, Saltillo, Mexico; St. Louis Assembly Plant, Fenton, Missouri (closed 2009).
🏆 Awards & Recognition
Recognitions
Reputation:
The 5.9L Cummins Turbo Diesel engine is highly regarded for its reliability and durability, often considered one of the best diesel engines of its era.
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