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Dodge RAM 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: RAM Year: 2004 Generation Generation Name: Third Generation (DR/DH/D9) Codes Chassis Code: DR 👋 Introduction Market Position Segment: Full-size Pickup Truck Target Audience: Fleet owners, mechanics, DIY enthusiasts, and owners seeking in-depth vehicle knowledge. Competitive Analysis Key Competitors: Ford F-Series, Chevrolet Silverado, GMC Sierra Key Features Value Proposition: Provides factory-level repair and maintenance information, enabling cost-effective vehicle ownership and upkeep. Technical Accuracy: Based on original manufacturer data, ensuring accuracy and reliability. 📋 Manual Details Coverage Areas Market Coverage: North America Page Count Estimated Page Count: 2000+ Manual Type Manual Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Management: Full diagnostics, component testing, and repair procedures for all gasoline engines. Powertrain: Detailed information on transmission (automatic and manual), transfer case, axles, and driveshafts. Suspension Steering: Front and rear suspension components, steering system, alignment specifications, and troubleshooting. Brakes: ABS system, hydraulic components, brake rotor/pad replacement, parking brake, and troubleshooting. Electrical Systems: Wiring diagrams, fuse/relay identification, power distribution, lighting, starting, charging, and accessory systems. Body Interior: Body panel removal/installation, interior trim, HVAC system, doors, windows, seats, and basic body repair. Diagnostic Troubleshooting: Extensive troubleshooting guides, diagnostic trouble codes (DTCs), and symptom-based repair procedures. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, and inspections. Engine Repair: Engine overhaul, cylinder head removal, timing chain/belt service, piston/ring replacement, and component diagnostics. Transmission Overhaul: Step-by-step instructions for disassembly, inspection, repair, and reassembly of automatic and manual transmissions. Brake System Repair: Caliper replacement, master cylinder service, ABS sensor diagnosis and replacement, and bleeding procedures. Electrical Diagnostics: Testing circuits, diagnosing faults with wiring diagrams, and troubleshooting electronic modules. Body Hardware Repair: Door lock actuator replacement, window regulator repair, and tailgate/liftgate servicing. Technical Depth Depth Level: Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Diagnostic Tools Required: Specifies necessary diagnostic tools, scan tools (e.g., DRB III), and specialized equipment. Torque Specifications: Detailed torque values for all critical fasteners throughout the vehicle. Clearances Tolerances: Provides factory specifications for engine component clearances, bearing tolerances, and suspension geometry. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick access to information. Print Quality Image Resolution: High-resolution for clear diagrams and illustrations. Illustration Type: Step-by-step illustrated instructions. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8 Engine Options 3.7L Magnum V6 Specs: 215 hp @ 4800 rpm, 235 lb-ft @ 4000 rpm, SOHC, 3 valves per cylinder 4.7L Magnum V8 Specs: 235 hp @ 4600 rpm, 295 lb-ft @ 3200 rpm, SOHC, 3 valves per cylinder 5.7L Hemi V8 Specs: 345 hp @ 5000 rpm, 375 lb-ft @ 4000 rpm, OHV, HEMI, 2 valves per cylinder Performance Fuel Induction: Sequential Multi-Port Fuel Injection (MPI) Fuel System Fuel Type: Unleaded gasoline Ignition System: Distributorless Ignition System (DIS) with individual coil-on-plug (COP) for HEMI Engine Management ECM Module: Various NGC (Next Generation Controller) variations depending on engine and transmission. 🔧 Transmission Standard Standard Transmission: 4-speed Automatic (42RE, 45RFE, 48RE depending on engine/model) Optional Optional Transmission: 5-speed Manual (NV3500 for V6, NV4500 for V8 on select models) Features Transmission Fluid Type: ATF+4 (Mopar) Transfer Case: NV241DHD (Heavy Duty) part-time 4WD system common. 📐 Dimensions Exterior Wheelbase Options: 134.5 inches (standard), 154.5 inches (long bed), 160.5 inches (Mega Cab) Overall Length Range: 222.4 - 248.4 inches (depending on configuration) Weights Curb Weight Range: Approximately 4,700 - 5,500 lbs Gvw Range: 6,500 lbs to 8,800 lbs (depending on configuration and payload package) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4/5 Stars (2004 Model) NHTSA Frontal Impact Passenger: 4/5 Stars (2004 Model) IIHS Frontal Offset: Good (as per available data for similar models in its generation) Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Passive Features Airbags: Standard front driver and passenger airbags. Seatbelts: 3-point height-adjustable front seat belts with pretensioners. 💡 Technology Features Infotainment Infotainment Options: Factory AM/FM/CD stereo system, optional Infinity sound system, and available premium audio with subwoofer. Navigation System: Optional factory navigation system available on higher trim levels. Driver Assistance Cruise Control: Standard cruise control on most models. Connectivity Auxiliary Input: Limited auxiliary inputs, typically an optional AUX jack on premium stereos. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics). Engine Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection. Spark Plug Replacement: 30,000 miles for conventional plugs, 100,000 miles for platinum/iridium plugs (varies by engine). Fluid Specifications Engine Oil Specification: SAE 5W-30 for 3.7L/4.7L, SAE 5W-20 for 5.7L HEMI (check manual for exact API service category). Coolant Specification: Chrysler/Mopar HOAT (Hybrid Organic Acid Technology)...
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Dodge RAM 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
RAM
Year:
2004
Generation
Generation Name:
Third Generation (DR/DH/D9)
Codes
Chassis Code:
DR
👋 Introduction
Market Position
Segment:
Full-size Pickup Truck
Target Audience:
Fleet owners, mechanics, DIY enthusiasts, and owners seeking in-depth vehicle knowledge.
Competitive Analysis
Key Competitors:
Ford F-Series, Chevrolet Silverado, GMC Sierra
Key Features
Value Proposition:
Provides factory-level repair and maintenance information, enabling cost-effective vehicle ownership and upkeep.
Technical Accuracy:
Based on original manufacturer data, ensuring accuracy and reliability.
📋 Manual Details
Coverage Areas
Market Coverage:
North America
Page Count
Estimated Page Count:
2000+
Manual Type
Manual Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Full diagnostics, component testing, and repair procedures for all gasoline engines.
Powertrain:
Detailed information on transmission (automatic and manual), transfer case, axles, and driveshafts.
Suspension Steering:
Front and rear suspension components, steering system, alignment specifications, and troubleshooting.
Brakes:
ABS system, hydraulic components, brake rotor/pad replacement, parking brake, and troubleshooting.
Electrical Systems:
Wiring diagrams, fuse/relay identification, power distribution, lighting, starting, charging, and accessory systems.
Body Interior:
Body panel removal/installation, interior trim, HVAC system, doors, windows, seats, and basic body repair.
Diagnostic Troubleshooting:
Extensive troubleshooting guides, diagnostic trouble codes (DTCs), and symptom-based repair procedures.
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, and inspections.
Engine Repair:
Engine overhaul, cylinder head removal, timing chain/belt service, piston/ring replacement, and component diagnostics.
Transmission Overhaul:
Step-by-step instructions for disassembly, inspection, repair, and reassembly of automatic and manual transmissions.
Brake System Repair:
Caliper replacement, master cylinder service, ABS sensor diagnosis and replacement, and bleeding procedures.
Electrical Diagnostics:
Testing circuits, diagnosing faults with wiring diagrams, and troubleshooting electronic modules.
Body Hardware Repair:
Door lock actuator replacement, window regulator repair, and tailgate/liftgate servicing.
Technical Depth
Depth Level:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Tools Required:
Specifies necessary diagnostic tools, scan tools (e.g., DRB III), and specialized equipment.
Torque Specifications:
Detailed torque values for all critical fasteners throughout the vehicle.
Clearances Tolerances:
Provides factory specifications for engine component clearances, bearing tolerances, and suspension geometry.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick access to information.
Print Quality
Image Resolution:
High-resolution for clear diagrams and illustrations.
Illustration Type:
Step-by-step illustrated instructions.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8
Engine Options
3.7L Magnum V6 Specs:
215 hp @ 4800 rpm, 235 lb-ft @ 4000 rpm, SOHC, 3 valves per cylinder
4.7L Magnum V8 Specs:
235 hp @ 4600 rpm, 295 lb-ft @ 3200 rpm, SOHC, 3 valves per cylinder
5.7L Hemi V8 Specs:
345 hp @ 5000 rpm, 375 lb-ft @ 4000 rpm, OHV, HEMI, 2 valves per cylinder
Performance
Fuel Induction:
Sequential Multi-Port Fuel Injection (MPI)
Fuel System
Fuel Type:
Unleaded gasoline
Ignition System:
Distributorless Ignition System (DIS) with individual coil-on-plug (COP) for HEMI
Engine Management
ECM Module:
Various NGC (Next Generation Controller) variations depending on engine and transmission.
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic (42RE, 45RFE, 48RE depending on engine/model)
Optional
Optional Transmission:
5-speed Manual (NV3500 for V6, NV4500 for V8 on select models)
Features
Transmission Fluid Type:
ATF+4 (Mopar)
Transfer Case:
NV241DHD (Heavy Duty) part-time 4WD system common.
📐 Dimensions
Exterior
Wheelbase Options:
134.5 inches (standard), 154.5 inches (long bed), 160.5 inches (Mega Cab)
Overall Length Range:
222.4 - 248.4 inches (depending on configuration)
Weights
Curb Weight Range:
Approximately 4,700 - 5,500 lbs
Gvw Range:
6,500 lbs to 8,800 lbs (depending on configuration and payload package)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4/5 Stars (2004 Model)
NHTSA Frontal Impact Passenger:
4/5 Stars (2004 Model)
IIHS Frontal Offset:
Good (as per available data for similar models in its generation)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Passive Features
Airbags:
Standard front driver and passenger airbags.
Seatbelts:
3-point height-adjustable front seat belts with pretensioners.
💡 Technology Features
Infotainment
Infotainment Options:
Factory AM/FM/CD stereo system, optional Infinity sound system, and available premium audio with subwoofer.
Navigation System:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Auxiliary Input:
Limited auxiliary inputs, typically an optional AUX jack on premium stereos.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics).
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement:
30,000 miles for conventional plugs, 100,000 miles for platinum/iridium plugs (varies by engine).
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 for 3.7L/4.7L, SAE 5W-20 for 5.7L HEMI (check manual for exact API service category).
Coolant Specification:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) or equivalent OAT coolant (Orange).
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Common Issues Summary:
Potential issues include transmission solenoid issues (45RFE/48RE), death wobble (steering/suspension components), rust on body panels, and HVAC blend door actuator failures.
Hemi Carbon Buildup:
Early 5.7L HEMI engines can experience carbon buildup on intake valves due to the cylinder deactivation system. Regular cleaning and oil changes are recommended.
Towing Related Wear:
Heavy towing can accelerate wear on suspension, brakes, and drivetrain components.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks dating back to the 1930s.
Model Evolution
Ram Nameplate Origin:
The RAM nameplate was introduced in 1981, evolving through multiple generations to become a leading pickup.
Third Generation Introduction:
The third generation (2002-2008) introduced a significant redesign with a more modern chassis and styling, including the HEMI engine option.
Production
Manufacturing Locations:
St. Louis Assembly, Missouri, and Warren Truck Assembly, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Segment Performance:
Consistently ranked among the top-selling full-size pickup trucks in North America.
Ratings
Consumer Reports Reliability:
Varies by specific year and engine, but generally average to below average for its class during this generation.
Certifications
Emission Standards:
Meets EPA and California Air Resources Board (CARB) emission standards for its model year.
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