Dodge Ram 1500-2500-3500 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500, 2500, 3500 Year: 2004 👋 Introduction Market Position Market Position: The 2004 Dodge Ram series was a highly competitive and popular line of full-size pickup trucks known for their robust construction, towing capabilities, and a range of powertrain options. This manual directly targets owners and technicians seeking authoritative, in-depth repair and maintenance information for these vehicles. Competitive Analysis Competitive Analysis: Competed directly with Ford F-Series and Chevrolet Silverado/GMC Sierra. The availability of powerful V8 and HEMI engines, along with a reputation for durability, made the Ram a strong contender. This manual provides the specific factory-level detail needed to maintain and repair these competitive advantages. Key Features Key Features: Comprehensive A-Z repair coverage, factory-engineer-level accuracy, digital PDF format for ease of use and portability, detailed diagrams and schematics, printable pages, zoomable images, essential for DIY repairs and professional servicing. Target Audience Target Audience: Dodge Ram owners (DIY enthusiasts) and professional automotive technicians specializing in Chrysler/Dodge vehicles. Value Proposition Value Proposition: Saves significant money on repair costs by empowering owners to perform maintenance and repairs themselves or by providing accurate information to mechanics, ensuring correct diagnostics and procedures are followed. 📋 Manual Details Coverage Areas Coverage Areas: All Dodge Ram 1500, 2500, and 3500 models for the 2004 model year. Page Count Page Count: Not specified, but described as 'COMPLETE' and containing 'comprehensive instructions'. Manual Type Manual Type: Official Full Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine (including all variants), Transmission (manual and automatic), Drivetrain (2WD/4WD), Brakes (ABS, standard), Suspension (front and rear), Steering, Fuel System, Exhaust System, Cooling System, HVAC (Heating, Ventilation, and Air Conditioning), Electrical System (including wiring schematics), Body and Chassis, Interior and Exterior Components, Diagnostic Procedures, Troubleshooting. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, component diagnostics, disassembly and reassembly of major and minor components, repair procedures for all systems, troubleshooting guides, replacement of parts, system adjustments, wiring diagram interpretation, torque specifications, fluid capacities and types, diagnostic trouble codes (DTCs). Technical Depth Technical Depth: Factory-level technical details, step-by-step instructions with diagrams and illustrations, covering from basic maintenance to complete rebuilds and advanced diagnostics, suitable for professional technicians and experienced DIY enthusiasts. Specific Procedures Specific Procedures: Front and rear axle service, differential repair, transfer case operation and repair, wheel bearing replacement, brake caliper and rotor service, power steering pump and rack/gearbox diagnosis, HVAC blower motor and evaporator core replacement, engine oil pan gasket replacement, cylinder head removal and installation, fuel injector testing and replacement, exhaust system component replacement, complete electrical system diagnostics using wiring schematics. Body And Frame Body And Frame: Includes procedures for body panel alignment, door and latch repair, interior trim removal, seat adjustment mechanisms, tailgate operation, frame inspection, and rust repair considerations. Lighting And Accessories Lighting And Accessories: Covers headlight/taillight bulb replacement, trailer wiring harness service, power window motor and regulator repair, power lock actuator diagnosis, horn system troubleshooting, and wiper system maintenance. Diagnostics Troubleshooting Diagnostics Troubleshooting: Comprehensive guides for diagnosing electrical faults, engine performance issues, transmission problems, and suspension noise using symptom-based troubleshooting charts and diagnostic trouble code (DTC) lookup tables. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-quality, printable pages allowing for enlarged images and specific section printing. Binding Type Binding Type: Digital (PDF) - No physical binding. Paper Type Paper Type: Not Applicable (Digital Format) Zoom Functionality Zoom Functionality: YES - PDF format allows users to zoom in on diagrams and images for detailed viewing and accurate work. Searchability Searchability: Implied by PDF format, allowing for keyword searches within the document for specific components or procedures. Modularity Modularity: YES - Users can print only the necessary pages, reducing the need to carry the entire manual in a workshop environment and preventing damage to the digital file. Delivery Method Delivery Method: Instant Download. Software Requirements Software Requirements: Adobe PDF Reader and WinZip (or equivalent decompression software) are required. Compatibility Compatibility: Compatible with all versions of Windows and Mac operating systems. ⚙️ Engine Specifications Primary Engine Primary Engine: 4.7L Magnum V8 (SOHC, 16-valve), 5.7L HEMI V8 (OHV, 16-valve). Optional Engine Optional Engine: 5.9L Cummins Turbo Diesel I6 (for 2500/3500 models). Performance Performance: Horsepower and torque vary by engine. The 4.7L V8 typically produced around 235-245 hp and 330-350 lb-ft of torque. The 5.7L HEMI offered approximately 345-370 hp and 375-400 lb-ft of torque. The 5.9L Cummins diesel provided significant torque, typically around 450-500 lb-ft at low RPM. Fuel System Fuel System: Electronic Fuel Injection (EFI) for gasoline engines. High-pressure common rail injection for the Cummins diesel. Engine Codes Engine Codes: 4.7L V8: ECH (non-PZEV), ECH (PZEV). 5.7L V8: EGD. 5.9L Cummins Diesel: A2, C2 (check VIN for exact code). Torque Specs Torque Specs: Crucial torque values for cylinder head bolts, main...

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Sku: 204529

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Tags: 2004 2500 Dodge International Truck Ram 1500 Ram 2500 Ram 3500 Truck Trucks

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 1500, 2500, 3500

Year:

👋 Introduction

Market Position

Market Position:

The 2004 Dodge Ram series was a highly competitive and popular line of full-size pickup trucks known for their robust construction, towing capabilities, and a range of powertrain options. This manual directly targets owners and technicians seeking authoritative, in-depth repair and maintenance information for these vehicles.

Competitive Analysis

Competitive Analysis:

Competed directly with Ford F-Series and Chevrolet Silverado/GMC Sierra. The availability of powerful V8 and HEMI engines, along with a reputation for durability, made the Ram a strong contender. This manual provides the specific factory-level detail needed to maintain and repair these competitive advantages.

Key Features

Key Features:

Comprehensive A-Z repair coverage, factory-engineer-level accuracy, digital PDF format for ease of use and portability, detailed diagrams and schematics, printable pages, zoomable images, essential for DIY repairs and professional servicing.

Target Audience

Target Audience:

Dodge Ram owners (DIY enthusiasts) and professional automotive technicians specializing in Chrysler/Dodge vehicles.

Value Proposition

Value Proposition:

Saves significant money on repair costs by empowering owners to perform maintenance and repairs themselves or by providing accurate information to mechanics, ensuring correct diagnostics and procedures are followed.

📋 Manual Details

Coverage Areas

Coverage Areas:

All Dodge Ram 1500, 2500, and 3500 models for the 2004 model year.

Page Count

Page Count:

Not specified, but described as 'COMPLETE' and containing 'comprehensive instructions'.

Manual Type

Manual Type:

Official Full Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine (including all variants), Transmission (manual and automatic), Drivetrain (2WD/4WD), Brakes (ABS, standard), Suspension (front and rear), Steering, Fuel System, Exhaust System, Cooling System, HVAC (Heating, Ventilation, and Air Conditioning), Electrical System (including wiring schematics), Body and Chassis, Interior and Exterior Components, Diagnostic Procedures, Troubleshooting.

Procedures Included

Procedures Included:

Routine maintenance, scheduled servicing, component diagnostics, disassembly and reassembly of major and minor components, repair procedures for all systems, troubleshooting guides, replacement of parts, system adjustments, wiring diagram interpretation, torque specifications, fluid capacities and types, diagnostic trouble codes (DTCs).

Technical Depth

Technical Depth:

Factory-level technical details, step-by-step instructions with diagrams and illustrations, covering from basic maintenance to complete rebuilds and advanced diagnostics, suitable for professional technicians and experienced DIY enthusiasts.

Specific Procedures

Specific Procedures:

Front and rear axle service, differential repair, transfer case operation and repair, wheel bearing replacement, brake caliper and rotor service, power steering pump and rack/gearbox diagnosis, HVAC blower motor and evaporator core replacement, engine oil pan gasket replacement, cylinder head removal and installation, fuel injector testing and replacement, exhaust system component replacement, complete electrical system diagnostics using wiring schematics.

Body And Frame

Body And Frame:

Includes procedures for body panel alignment, door and latch repair, interior trim removal, seat adjustment mechanisms, tailgate operation, frame inspection, and rust repair considerations.

Lighting And Accessories

Lighting And Accessories:

Covers headlight/taillight bulb replacement, trailer wiring harness service, power window motor and regulator repair, power lock actuator diagnosis, horn system troubleshooting, and wiper system maintenance.

Diagnostics Troubleshooting

Diagnostics Troubleshooting:

Comprehensive guides for diagnosing electrical faults, engine performance issues, transmission problems, and suspension noise using symptom-based troubleshooting charts and diagnostic trouble code (DTC) lookup tables.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-quality, printable pages allowing for enlarged images and specific section printing.

Binding Type

Binding Type:

Digital (PDF) - No physical binding.

Paper Type

Paper Type:

Not Applicable (Digital Format)

Zoom Functionality

Zoom Functionality:

YES - PDF format allows users to zoom in on diagrams and images for detailed viewing and accurate work.

Searchability

Searchability:

Implied by PDF format, allowing for keyword searches within the document for specific components or procedures.

Modularity

Modularity:

YES - Users can print only the necessary pages, reducing the need to carry the entire manual in a workshop environment and preventing damage to the digital file.

Delivery Method

Delivery Method:

Instant Download.

Software Requirements

Software Requirements:

Adobe PDF Reader and WinZip (or equivalent decompression software) are required.

Compatibility

Compatibility:

Compatible with all versions of Windows and Mac operating systems.

⚙️ Engine Specifications

Primary Engine

Primary Engine:

4.7L Magnum V8 (SOHC, 16-valve), 5.7L HEMI V8 (OHV, 16-valve).

Optional Engine

Optional Engine:

5.9L Cummins Turbo Diesel I6 (for 2500/3500 models).

Performance

Performance:

Horsepower and torque vary by engine. The 4.7L V8 typically produced around 235-245 hp and 330-350 lb-ft of torque. The 5.7L HEMI offered approximately 345-370 hp and 375-400 lb-ft of torque. The 5.9L Cummins diesel provided significant torque, typically around 450-500 lb-ft at low RPM.

Fuel System

Fuel System:

Electronic Fuel Injection (EFI) for gasoline engines. High-pressure common rail injection for the Cummins diesel.

Engine Codes

Engine Codes:

4.7L V8: ECH (non-PZEV), ECH (PZEV). 5.7L V8: EGD. 5.9L Cummins Diesel: A2, C2 (check VIN for exact code).

Torque Specs

Torque Specs:

Crucial torque values for cylinder head bolts, main bearing caps, connecting rod bolts, intake and exhaust manifold bolts, and other critical engine components are provided within the manual.

Engine Displacements

Engine Displacements:

4.7 Liter (287 cubic inches), 5.7 Liter (345 cubic inches), 5.9 Liter (359 cubic inches).

🔧 Transmission

Standard

Standard:

5-speed manual transmission (NV3500 for 1500, G56 for 2500/3500).

Optional

Optional:

4-speed automatic transmission (45RFE/48RE for gasoline engines), 5-speed automatic transmission (2700/2705 for Cummins diesel).

Features

Features:

Overdrive gears, Tow/Haul mode (on automatics), electronic shift control for 4WD systems.

Transmission Codes

Transmission Codes:

4-Speed Automatic: 45RFE, 48RE. 5-Speed Manual: NV3500, G56. 5-Speed Automatic (Diesel): 2700, 2705.

Gear Ratios

Gear Ratios:

Specific gear ratios for all available manual and automatic transmissions are detailed, crucial for performance tuning and diagnostic analysis.

📐 Dimensions

Exterior

Exterior:

Varies by cab configuration (Regular, Club, Mega Cab) and bed length (short, standard, long). Ground clearance varies, but generally robust for off-road capability. Specific dimensions such as overall length, width, and height are detailed within the manual based on configuration.

Interior

Interior:

Spacious cabin options, particularly the Mega Cab, offering significant passenger room. Seating configurations and dashboard layout details are covered for diagnosis and repair.

Cargo

Cargo:

Bed lengths typically range from 6.3 ft to 8.0 ft. Payload capacity varies significantly based on model (1500, 2500, 3500) and configuration, with 3500 models offering the highest capacities for heavy-duty use.

Weights

Weights:

Curb weight and Gross Vehicle Weight Rating (GVWR) vary by model and configuration, with 3500 models having significantly higher GVWRs for heavy-duty towing and hauling. Gross Combined Weight Rating (GCWR) also varies and is crucial for towing applications.

Wheelbase

Wheelbase:

Wheelbase varies by cab and bed configuration, with common lengths including 135.0 inches (regular cab, short bed), 140.5 inches (regular cab, long bed), and 160.5 inches (club cab, long bed). Mega Cab configurations will have longer wheelbases.

Track Width

Track Width:

Front and rear track widths vary slightly by model and suspension type, with front track width typically around 67-68 inches and rear track width around 66-67 inches.

🛡️ Safety Features

Ratings

Ratings:

NHTSA and IIHS crash test ratings for the 2004 model year are available and detailed in the manual for reference regarding structural integrity and occupant protection. Generally good for its class, with variations based on equipment.

Active Features

Active Features:

Anti-lock Braking System (ABS) on all wheels, available integrated trailer brake controller, limited-slip differential options.

Passive Features

Passive Features:

Front airbags, optional side curtain airbags (more common on higher trims/Mega Cab), seatbelt pretensioners, reinforced cabin structure.

Tire Sizes

Tire Sizes:

Common factory tire sizes include P265/70R17, LT265/70R17, P275/60R20, and LT275/70R18, with specific sizes dependent on trim level and payload/towing packages.

Wheel Bolt Pattern

Wheel Bolt Pattern:

5x5.5 inches (5x139.7 mm) for most models. 8-lug pattern (8x6.5 inches or 8x165.1 mm) for heavy-duty 2500/3500 models with diesel engines or specific heavy-duty gas configurations.

Braking System

Braking System:

Disc brakes front and rear, with ventilated front rotors. Specifications for brake pad replacement, rotor resurfacing/replacement, caliper service, brake fluid bleeding procedures, and ABS system diagnostics are extensively covered.

💡 Technology Features

Infotainment

Infotainment:

Base models featured a standard AM/FM radio with CD player. Higher trims offered premium audio systems, optional satellite radio, and a multi-function display for vehicle information. Navigation systems were rare or aftermarket for this year.

Driver Assistance

Driver Assistance:

Limited by modern standards. Primarily focused on the ABS system. Parking sensors were not a common factory option. Cruise control was standard on most trims.

Connectivity

Connectivity:

Basic connectivity features were available, such as auxiliary input for audio devices on some models or early forms of hands-free calling (Uconnect system was beginning to be introduced around this time, but less common on trucks). Primarily focused on vehicle operation and diagnostics.

Instrument Cluster

Instrument Cluster:

Information on gauge cluster removal, bulb replacement, speedometer calibration, and warning light diagnostics (e.g., Check Engine, ABS, Airbag lights).

🔧 Maintenance

Service Intervals

Service Intervals:

Engine oil changes every 3,000-7,500 miles (depending on oil type and driving conditions), transmission fluid and filter service every 30,000-60,000 miles, coolant flushes every 30,000-100,000 miles (depending on coolant type), spark plug replacement typically between 60,000-100,000 miles. The manual provides specific intervals for all maintenance items.

Fluid Specifications

Fluid Specifications:

Engine Oil: SAE 5W-30 (for 4.7L and 5.7L gasoline, check manual for specific API service categories), SAE 15W-40 or 5W-40 synthetic for 5.9L Cummins diesel. Transmission Fluid: ATF+4 (for automatic transmissions), manual transmission fluid specifications are detailed. Coolant: HOAT (Hybrid Organic Acid Technology) antifreeze/coolant, typically Mopar OAT. Brake Fluid: DOT 3. Power Steering Fluid: ATF+4 or Mopar power steering fluid.

Known Issues

Known Issues:

Common issues can include: death wobble (front suspension/steering linkage), radiator leaks, ABS sensor failures, exhaust manifold leaks (especially on HEMI engines), transmission issues (e.g., torque converter shudder), and injector pump failures on older Cummins models (though 2004 is generally robust). The manual addresses diagnosis and repair for these.

Oil Capacity

Oil Capacity:

4.7L V8: 6 quarts (5.7 liters) with filter. 5.7L V8: 7 quarts (6.6 liters) with filter. 5.9L Cummins Diesel: 11 quarts (10.4 liters) with filter.

Coolant Capacity

Coolant Capacity:

Approximately 14-17 quarts (13.2-16.1 liters) for V8 gasoline engines, and 20-22 quarts (18.9-20.8 liters) for the 5.9L Cummins diesel, depending on the cooling system configuration.

Transmission Fluid Capacity

Transmission Fluid Capacity:

Automatic transmissions typically hold 11-13 quarts (10.4-12.3 liters) for a fluid and filter change. Manual transmissions require specific gear oil quantities detailed in the manual.

Filter Part Numbers

Filter Part Numbers:

While specific part numbers vary by manufacturer (Mopar, Wix, etc.), the manual will guide users on identifying the correct oil filter (e.g., Mopar MO-090 for 4.7L/5.7L, Mopar 3937767 for 5.9L Cummins), fuel filter, and transmission filter for each engine/transmission combination.

Chassis Lubrication

Chassis Lubrication:

Details specific points requiring grease lubrication, such as ball joints, tie rod ends, and U-joints (on driveshafts), and specifies the type of grease to be used.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Dodge, as part of Chrysler, has a long history in the pickup truck market, with the Ram line evolving significantly since its introduction. Known for powerful engines and distinct styling.

Model Evolution

Model Evolution:

The 2004 model year falls within the third generation of the Dodge Ram (1994-2001, second generation; 2002-2008, third generation). This generation saw significant redesigns, including the introduction of the HEMI engine and the Mega Cab option, enhancing its competitive edge.

Production

Production:

Produced in North America, with primary manufacturing facilities including Warren, Michigan, and Saltillo, Mexico.

Vin Decoder

Vin Decoder:

The manual may include information or references to VIN decoding to identify specific vehicle configurations, engine types, and manufacturing details.

Generation Codes

Generation Codes:

Third Generation Dodge Ram (2002-2008) - DN Platform.

🏆 Awards & Recognition

Recognitions

Recognitions:

The Dodge Ram consistently received positive reviews for its styling, interior comfort (especially Mega Cab), and powertrain options, particularly the HEMI and Cummins engines. It was often lauded for its towing and hauling capabilities, competing strongly in its segment.