DODGE RAM 2500 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2004 Codes Platform: BR/BE 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck Target Audience: Commercial users, fleet operators, towing enthusiasts, DIY mechanics, and owners seeking detailed repair information. Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Strengths: Robust chassis, strong towing and hauling capabilities, powerful engine options (especially the Cummins diesel), durable construction. Manual Value Proposition: Provides essential knowledge for maintaining and repairing the vehicle, reducing reliance on dealership service, and extending vehicle lifespan. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Downloadable PDF Page Count: Estimated 1000+ pages (typical for comprehensive service manuals of this era) Manual Specifications File Format Quality: High-resolution PDF with searchable text and clear, legible diagrams. Print Quality: Designed for clear printing, with scalable diagrams and readable text. Binding Type: N/A (Downloadable PDF) Paper Type: N/A (Downloadable PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, diagnosis, cylinder head, block assembly, pistons, connecting rods, crankshaft, lubrication system, cooling system, fuel delivery system (mechanical components), emission control systems (mechanical components). Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostics, sensors (MAP, TPS, CKP, CMP, O2, etc.), actuators, wiring diagrams, troubleshooting. Transmission Manual: NV4500 (for gasoline engines), G56 (for Cummins diesel) - clutch system, gear selection, internal components, removal and installation, diagnostic procedures, fluid specifications. Transmission Automatic: 48RE (for gasoline and some diesel engines), 47RE (for gasoline engines) - torque converter, hydraulic control systems, valve body, planetary gear sets, removal and installation, diagnostic procedures, fluid specifications, solenoids. Drivetrain: Transfer case operation and service (NV241, NV271, NV273), drive shafts, U-joints, rear axle (Dana 70HD, Dana 80), front axle (Dana 60), differentials, wheel hubs, bearing service. Brakes: Front and rear brake systems (disc/drum), Anti-lock Braking System (ABS) components and diagnosis, brake fluid specifications, master cylinder, brake lines, calipers, pads, rotors, parking brake system. Suspension: Front and rear suspension systems, coil springs, leaf springs, shock absorbers, control arms, ball joints, bushings, steering knuckles, alignment specifications, troubleshooting. Steering: Power steering system, steering gear (Recirculating ball type), steering column, tie rod ends, drag link, steering fluid specifications, troubleshooting. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, mirrors, exterior trim, rust repair, body repair procedures, paint codes, alignment. Body Interior: Dashboard, seats, carpets, headliner, door panels, interior trim, climate control system components (HVAC), seat belts, airbag system components (diagnosis and removal/installation precautions). Electrical Chassis: Lighting system (headlights, taillights, interior lights), horn, wipers, power windows, power locks, mirrors, instrument cluster, warning lights, fuse box and relay locations, wiring diagrams for chassis components. Electrical Comfort Convenience: Audio system, power accessories, remote keyless entry (RKE) system, interior lighting, power mirrors, cruise control, security system. Diagnostics Troubleshooting: Systematic diagnostic charts, fault codes (OBD-II), component testing procedures, wiring harness testing, common problems and solutions, diagnostic tool usage. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, fuel filter replacement, coolant checks and replacement, brake fluid checks, tire rotation and pressure checks, lubrication points, battery maintenance. Component Replacement: Engine parts (spark plugs, belts, hoses, water pump, alternator, starter), transmission fluid and filter, brake pads and rotors, suspension components (shocks, ball joints), exhaust system components, fuel pump. Major Repairs: Engine overhaul (e.g., head gasket replacement, piston ring replacement), transmission rebuild (automatic and manual), differential overhaul, power steering pump replacement, ABS module replacement, HVAC blower motor replacement. Diagnostic Procedures: Using scan tools, interpreting diagnostic trouble codes (DTCs), performing circuit tests, voltage drop tests, continuity tests, pressure tests (fuel, oil, coolant), component resistance checks. Troubleshooting Guides: Step-by-step guides for diagnosing symptoms like no-start conditions, poor performance, unusual noises, brake issues, electrical problems, HVAC malfunctions. Torque Specifications: Precise torque values for critical fasteners throughout the vehicle, including engine components, drivetrain, suspension, brakes, and chassis. Special Tools: Identification and usage of specialized tools required for specific repair procedures, such as bearing pullers, fuel line disconnect tools, engine timing tools, etc. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, including connector pinouts, wire colors, and component locations. Technical Depth Depth Level: Comprehensive (from basic maintenance to complete overhaul and advanced diagnostics) Detail Level: Detailed, step-by-step instructions with accompanying diagrams and illustrations. Diagnostic Capability: Advanced diagnostic procedures, including troubleshooting flowcharts and specific tests for electronic control modules (ECMs). ⚙️ Engine Specifications Primary Engine Gasoline Option 1: 8.0L (488 ci) V10 Magnum (370 hp @ 4600 rpm, 450 lb-ft @ 3200 rpm) Gasoline Option 2: 5.7L (345 ci) HEMI V8 (345 hp @ 5400 rpm, 375 lb-ft @ 4000 rpm) - Introduced mid-year 2004 Diesel Option: 5.9L (359 ci) Cummins Turbo-Diesel I6 (235 hp @ 2900 rpm, 460 lb-ft @ 1400 rpm for manual transmission, 250 hp @ 2900 rpm, 460 lb-ft @ 1400 rpm for automatic transmission) Performance...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Year:

Codes

Platform:

BR/BE

👋 Introduction

Market Position

Segment:

Heavy-Duty Pickup Truck

Target Audience:

Commercial users, fleet operators, towing enthusiasts, DIY mechanics, and owners seeking detailed repair information.

Competitive Analysis

Key Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.

Key Features

Vehicle Strengths:

Robust chassis, strong towing and hauling capabilities, powerful engine options (especially the Cummins diesel), durable construction.

Manual Value Proposition:

Provides essential knowledge for maintaining and repairing the vehicle, reducing reliance on dealership service, and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Downloadable PDF

Page Count:

Estimated 1000+ pages (typical for comprehensive service manuals of this era)

Manual Specifications

File Format Quality:

High-resolution PDF with searchable text and clear, legible diagrams.

Print Quality:

Designed for clear printing, with scalable diagrams and readable text.

Binding Type:

N/A (Downloadable PDF)

Paper Type:

N/A (Downloadable PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, diagnosis, cylinder head, block assembly, pistons, connecting rods, crankshaft, lubrication system, cooling system, fuel delivery system (mechanical components), emission control systems (mechanical components).

Engine Electrical:

Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostics, sensors (MAP, TPS, CKP, CMP, O2, etc.), actuators, wiring diagrams, troubleshooting.

Transmission Manual:

NV4500 (for gasoline engines), G56 (for Cummins diesel) - clutch system, gear selection, internal components, removal and installation, diagnostic procedures, fluid specifications.

Transmission Automatic:

48RE (for gasoline and some diesel engines), 47RE (for gasoline engines) - torque converter, hydraulic control systems, valve body, planetary gear sets, removal and installation, diagnostic procedures, fluid specifications, solenoids.

Drivetrain:

Transfer case operation and service (NV241, NV271, NV273), drive shafts, U-joints, rear axle (Dana 70HD, Dana 80), front axle (Dana 60), differentials, wheel hubs, bearing service.

Brakes:

Front and rear brake systems (disc/drum), Anti-lock Braking System (ABS) components and diagnosis, brake fluid specifications, master cylinder, brake lines, calipers, pads, rotors, parking brake system.

Suspension:

Front and rear suspension systems, coil springs, leaf springs, shock absorbers, control arms, ball joints, bushings, steering knuckles, alignment specifications, troubleshooting.

Steering:

Power steering system, steering gear (Recirculating ball type), steering column, tie rod ends, drag link, steering fluid specifications, troubleshooting.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, glass, mirrors, exterior trim, rust repair, body repair procedures, paint codes, alignment.

Body Interior:

Dashboard, seats, carpets, headliner, door panels, interior trim, climate control system components (HVAC), seat belts, airbag system components (diagnosis and removal/installation precautions).

Electrical Chassis:

Lighting system (headlights, taillights, interior lights), horn, wipers, power windows, power locks, mirrors, instrument cluster, warning lights, fuse box and relay locations, wiring diagrams for chassis components.

Electrical Comfort Convenience:

Audio system, power accessories, remote keyless entry (RKE) system, interior lighting, power mirrors, cruise control, security system.

Diagnostics Troubleshooting:

Systematic diagnostic charts, fault codes (OBD-II), component testing procedures, wiring harness testing, common problems and solutions, diagnostic tool usage.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, coolant checks and replacement, brake fluid checks, tire rotation and pressure checks, lubrication points, battery maintenance.

Component Replacement:

Engine parts (spark plugs, belts, hoses, water pump, alternator, starter), transmission fluid and filter, brake pads and rotors, suspension components (shocks, ball joints), exhaust system components, fuel pump.

Major Repairs:

Engine overhaul (e.g., head gasket replacement, piston ring replacement), transmission rebuild (automatic and manual), differential overhaul, power steering pump replacement, ABS module replacement, HVAC blower motor replacement.

Diagnostic Procedures:

Using scan tools, interpreting diagnostic trouble codes (DTCs), performing circuit tests, voltage drop tests, continuity tests, pressure tests (fuel, oil, coolant), component resistance checks.

Troubleshooting Guides:

Step-by-step guides for diagnosing symptoms like no-start conditions, poor performance, unusual noises, brake issues, electrical problems, HVAC malfunctions.

Torque Specifications:

Precise torque values for critical fasteners throughout the vehicle, including engine components, drivetrain, suspension, brakes, and chassis.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures, such as bearing pullers, fuel line disconnect tools, engine timing tools, etc.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems, including connector pinouts, wire colors, and component locations.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete overhaul and advanced diagnostics)

Detail Level:

Detailed, step-by-step instructions with accompanying diagrams and illustrations.

Diagnostic Capability:

Advanced diagnostic procedures, including troubleshooting flowcharts and specific tests for electronic control modules (ECMs).

⚙️ Engine Specifications

Primary Engine

Gasoline Option 1:

8.0L (488 ci) V10 Magnum (370 hp @ 4600 rpm, 450 lb-ft @ 3200 rpm)

Gasoline Option 2:

5.7L (345 ci) HEMI V8 (345 hp @ 5400 rpm, 375 lb-ft @ 4000 rpm) - Introduced mid-year 2004

Diesel Option:

5.9L (359 ci) Cummins Turbo-Diesel I6 (235 hp @ 2900 rpm, 460 lb-ft @ 1400 rpm for manual transmission, 250 hp @ 2900 rpm, 460 lb-ft @ 1400 rpm for automatic transmission)

Performance

Fuel Type:

Gasoline, Diesel

Fuel System

Gasoline Fuel Delivery:

Multi-point Fuel Injection (MPI)

Diesel Fuel Delivery:

High-pressure injection system (Bosch VP44 injection pump)

🔧 Transmission

Standard

Gasoline Engines:

5-speed manual (NV4500 on 8.0L V10, potentially 6-speed manual on some 5.7L HEMI configurations)

Diesel Engine:

5-speed manual (NV4500 or G56 for Cummins)

Optional

Gasoline Engines:

4-speed automatic (47RE)

Diesel Engine:

4-speed automatic (48RE)

Features

Transfer Case Options:

2WD, 4WD Part-time (NV241), 4WD Full-time (NV241DHD), Electronic Shift-on-the-Fly (ESOF) 4WD (NV271/NV273)

📐 Dimensions

Exterior

Wheelbase:

Varies by configuration (e.g., 131.0 inches for Regular Cab, 140.5 inches for Quad Cab Short Bed, 160.5 inches for Quad Cab Long Bed)

Overall Length:

Varies by configuration (e.g., 225.0 inches for Regular Cab Short Bed to 259.0 inches for Quad Cab Long Bed)

Overall Width:

Approx. 79.1 inches

Overall Height:

Approx. 75.0 - 78.0 inches

Weights

Curb Weight:

Varies significantly by configuration (e.g., 5,500 - 7,500+ lbs)

Gross Vehicle Weight Rating:

8,800 lbs to 11,000+ lbs (depending on configuration)

Max Towing Capacity:

Up to 13,000+ lbs (properly equipped)

Max Payload Capacity:

Up to 4,000+ lbs (properly equipped)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star rating (for certain configurations)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Trailer Brake Controller Prep:

Optional integrated trailer brake controller harness and wiring.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Front and rear seat belts, pretensioners for front seats.

Construction:

Body-on-frame construction for enhanced durability and towing stability.

💡 Technology Features

Infotainment

Audio Systems:

Factory AM/FM/CD player, optional cassette player, Sirius Satellite Radio available on some trims. Premium Infinity audio systems were an option.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Trailer Lighting Connectors:

Standard trailer wiring harness connector (7-pin and 4-pin available).

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations).

Oil Change Diesel:

Every 7,500 miles or 6 months (synthetic diesel oil recommended for improved performance and protection).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on inspection.

Fuel Filter Replacement Gasoline:

Every 30,000-60,000 miles (in-tank).

Fuel Filter Replacement Diesel:

Every 15,000-30,000 miles (typically 2 filters: primary and secondary, recommended replacement is crucial for VP44 pump longevity).

Coolant Replacement:

Every 30,000-100,000 miles or 2-5 years, depending on coolant type (HOAT recommended).

Transmission Fluid Change Auto:

Every 30,000-60,000 miles (ATF+4 recommended).

Transmission Fluid Change Manual:

Every 60,000-100,000 miles (appropriate gear oil, e.g., GL-4 for NV4500).

Fluid Specifications

Engine Oil Gasoline V10:

SAE 10W-30 or 10W-40, API Service SG or higher (e.g., Valvoline Synthetic Blend 10W-30 is popular).

Engine Oil Gasoline Hemi:

SAE 5W-30, API Service SL or higher.

Engine Oil Diesel:

SAE 15W-40, API Service CI-4 or CH-4 (e.g., Mobil Delvac 1300 Super 15W-40, or a high-quality synthetic like Amsoil or Lucas).

Transmission Fluid Automatic:

Chrysler ATF+4

Transmission Fluid Manual Nv4500:

API GL-4, SAE 75W-90 gear oil (e.g., Royal Purple Synchromax, Red Line MTL).

Transmission Fluid Manual G56:

API GL-3 or GL-4, SAE 75W-85 or 75W-90 gear oil.

Transfer Case Fluid:

ATF+4 (for NV241, NV271, NV273)

Rear Axle Fluid:

SAE 75W-90 synthetic gear oil (API GL-5), with limited-slip additive if equipped with a Sure-Grip differential.

Power Steering Fluid:

Chrysler ATF+4 or Mopar Power Steering Fluid.

Known Issues

Diesel Vp44 Pump:

The 5.9L Cummins VP44 injection pump is known to be sensitive to fuel pressure drops and fuel quality, often leading to premature failure. Proper fuel filtration and maintaining adequate fuel pressure is critical.

Transmission Nv4500 3Rd Gear செல:

Some NV4500 manual transmissions can experience issues with the 3rd gear synchronizer or lockout ring, leading to difficulty shifting into 3rd gear. An aftermarket upgrade kit is available.

Automatic Transmission Heat:

Automatic transmissions (47RE/48RE) can be prone to overheating under heavy towing loads, necessitating the installation of an auxiliary transmission cooler.

Rear Main Seal Leaks:

Some Cummins diesel engines can develop leaks from the rear main seal, particularly with higher mileage.

Uhc Diesel Fuel Filter Housing:

The Under Hood Cooler (UHC) diesel fuel filter housing can develop cracks, leading to fuel leaks and potential air ingestion into the fuel system, which is detrimental to the VP44.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing durable and capable trucks, with the Ram line established in 1981.

Model Evolution

Third Generation Ram:

The 2004 model year falls within the third generation (2002-2008) of the Dodge Ram, which introduced significant redesigns including a larger cab, updated styling, and new powertrain options like the HEMI V8.

Production

Manufacturing Location:

Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA.