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2004 Dodge Durango Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Durango Year: 2004 Codes Platform: DN (second generation) 👋 Introduction Market Position Segment: Mid-size SUV Key Competitors: Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Nissan Pathfinder Key Features Platform Sharing: Shares platform with the Dodge Ram pickup truck (second generation). Powertrain Options: Offered with a choice of potent V8 engines, including the HEMI. Body Styles: Available as a 4-door SUV, typically with three rows of seating. 📋 Manual Details Coverage Areas General Coverage: Complete service and repair for 2004 Dodge Durango Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital PDF (Searchable) 📖 Manual Coverage Systems Covered Powertrain: Engine (4.7L V8, 5.7L HEMI V8), Transmission (45RFE/545RFE Automatic), Drivetrain (RWD, AWD) Chassis: Suspension (Independent Front, Multi-Link Rear), Steering, Brakes (ABS, Front Disc, Rear Disc) Electrical: Wiring Diagrams, Powertrain Control Module (PCM), Body Control Module (BCM), Ignition System, Lighting, Accessories, Diagnostics Body: Exterior Body Panels, Interior Trim, HVAC System, Seats, Doors, Glass Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Service, Belt Inspection and Replacement Diagnostics: Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, component testing Repair: Engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical component repair Special Tools: Identification and usage of special tools for specific repair procedures Technical Depth Depth: Comprehensive: From basic fluid changes to complete engine and transmission overhauls, including electrical system diagnostics and repair. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans of original factory documents, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Searchability Text Search: Fully searchable text allows for quick access to specific information. ⚙️ Engine Specifications Primary Engine Engine Code 1: EHB (4.7L Magnum V8) Displacement 1: 4.7 Liters (287 cubic inches) Configuration 1: V8 Horsepower 1: 230 hp @ 4500 rpm (approx.) Torque 1: 300 lb-ft @ 3200 rpm (approx.) Fuel System 1: Sequential Electronic Fuel Injection (SEFI) Optional Engine Engine Code 2: EVM (5.7L HEMI V8) Displacement 2: 5.7 Liters (345 cubic inches) Configuration 2: V8 Horsepower 2: 345 hp @ 5000 rpm (approx.) Torque 2: 375 lb-ft @ 4000 rpm (approx.) Fuel System 2: Sequential Electronic Fuel Injection (SEFI) General Engine Management: Chrysler's NGC (Next Generation Controller) Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Type: 45RFE / 545RFE Automatic Transmission Gear Ratios 45Rfe: 1st: 3.00, 2nd: 1.67, 3rd: 1.00, 4th: 0.75, Reverse: 2.20 Gear Ratios 545Rfe: 1st: 3.75, 2nd: 2.27, 3rd: 1.51, 4th: 1.00, 5th: 0.84, Reverse: 3.00 (Note: 545RFE is a 5-speed) Features Control Type: Electronically controlled with overdrive Fluid Specification Fluid Type: ATF+4 (Automatic Transmission Fluid, Type 9602) Capacity Fluid Capacity: Approximately 10.9 liters (11.5 US quarts) for initial fill. 📐 Dimensions Exterior Wheelbase: 119.8 inches (3043 mm) Length: 193.4 inches (4912 mm) Width: 77.1 inches (1958 mm) Height: 72.5 inches (1841 mm) Weights Curb Weight Min: 4,749 lbs (2154 kg) (4.7L V8 RWD) Gross Vehicle Weight Rating Max: 6,500 lbs (2948 kg) Cargo Cargo Volume Behind 1St Row: 87.5 cubic feet (2.48 m³) Cargo Volume Behind 2Nd Row: 41.9 cubic feet (1.19 m³) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 4/5 stars (for equipped models) IIHS Small Overlap Front: Not Recommended (based on similar era models) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Stability Control: Optional Electronic Stability Program (ESP) Passive Features Airbags: Frontal airbags for driver and passenger, optional side curtain airbags. Seat Belts: Three-point seat belts in all seating positions. 💡 Technology Features Infotainment Audio System: Available premium audio systems (e.g., Boston Acoustics), CD player, AM/FM radio. Navigation: Optional GPS navigation system available on higher trim levels. Driver Assistance Parking Assist: Optional rear parking assist sensors. Connectivity Auxiliary Input: Optional auxiliary audio input jack. Comfort Features Seating: Available leather-trimmed seats, heated front seats, power adjustable driver's seat. Climate Control: Manual or dual-zone automatic climate control. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 to 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specifics). Engine Air Filter Replacement: Inspect every 15,000 miles, replace as needed (typically every 30,000 miles). Spark Plug Replacement: 4.7L V8: Every 100,000 miles. 5.7L HEMI V8: Every 100,000 miles (using specific HEMI spark plugs). Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic or Conventional (check owner's manual for specific viscosity and API service classification). Engine Oil Capacity: 4.7L: 6.0 Quarts (5.7 Liters). 5.7L HEMI: 7.0 Quarts (6.6 Liters). Coolant Type: Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, or equivalent meeting Chrysler MS-9769 specification. Brake Fluid Type: DOT 3 Known Issues Common Issue 1: Cooling system leaks (radiator, water pump, heater core) due to aging components. Common Issue 2: Power steering pump leaks or noise....
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2004 Dodge Durango Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Durango
Year:
2004
Codes
Platform:
DN (second generation)
👋 Introduction
Market Position
Segment:
Mid-size SUV
Key Competitors:
Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Nissan Pathfinder
Key Features
Platform Sharing:
Shares platform with the Dodge Ram pickup truck (second generation).
Powertrain Options:
Offered with a choice of potent V8 engines, including the HEMI.
Body Styles:
Available as a 4-door SUV, typically with three rows of seating.
📋 Manual Details
Coverage Areas
General Coverage:
Complete service and repair for 2004 Dodge Durango
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital PDF (Searchable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4.7L V8, 5.7L HEMI V8), Transmission (45RFE/545RFE Automatic), Drivetrain (RWD, AWD)
Chassis:
Suspension (Independent Front, Multi-Link Rear), Steering, Brakes (ABS, Front Disc, Rear Disc)
Electrical:
Wiring Diagrams, Powertrain Control Module (PCM), Body Control Module (BCM), Ignition System, Lighting, Accessories, Diagnostics
Body:
Exterior Body Panels, Interior Trim, HVAC System, Seats, Doors, Glass
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Service, Belt Inspection and Replacement
Diagnostics:
Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, component testing
Repair:
Engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical component repair
Special Tools:
Identification and usage of special tools for specific repair procedures
Technical Depth
Depth:
Comprehensive: From basic fluid changes to complete engine and transmission overhauls, including electrical system diagnostics and repair.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans of original factory documents, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Searchability
Text Search:
Fully searchable text allows for quick access to specific information.
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EHB (4.7L Magnum V8)
Displacement 1:
4.7 Liters (287 cubic inches)
Configuration 1:
V8
Horsepower 1:
230 hp @ 4500 rpm (approx.)
Torque 1:
300 lb-ft @ 3200 rpm (approx.)
Fuel System 1:
Sequential Electronic Fuel Injection (SEFI)
Optional Engine
Engine Code 2:
EVM (5.7L HEMI V8)
Displacement 2:
5.7 Liters (345 cubic inches)
Configuration 2:
V8
Horsepower 2:
345 hp @ 5000 rpm (approx.)
Torque 2:
375 lb-ft @ 4000 rpm (approx.)
Fuel System 2:
Sequential Electronic Fuel Injection (SEFI)
General
Engine Management:
Chrysler's NGC (Next Generation Controller) Powertrain Control Module (PCM)
🔧 Transmission
Standard
Transmission Type:
45RFE / 545RFE Automatic Transmission
Gear Ratios 45Rfe:
1st: 3.00, 2nd: 1.67, 3rd: 1.00, 4th: 0.75, Reverse: 2.20
Gear Ratios 545Rfe:
1st: 3.75, 2nd: 2.27, 3rd: 1.51, 4th: 1.00, 5th: 0.84, Reverse: 3.00 (Note: 545RFE is a 5-speed)
Features
Control Type:
Electronically controlled with overdrive
Fluid Specification
Fluid Type:
ATF+4 (Automatic Transmission Fluid, Type 9602)
Capacity
Fluid Capacity:
Approximately 10.9 liters (11.5 US quarts) for initial fill.
📐 Dimensions
Exterior
Wheelbase:
119.8 inches (3043 mm)
Length:
193.4 inches (4912 mm)
Width:
77.1 inches (1958 mm)
Height:
72.5 inches (1841 mm)
Weights
Curb Weight Min:
4,749 lbs (2154 kg) (4.7L V8 RWD)
Gross Vehicle Weight Rating Max:
6,500 lbs (2948 kg)
Cargo
Cargo Volume Behind 1St Row:
87.5 cubic feet (2.48 m³)
Cargo Volume Behind 2Nd Row:
41.9 cubic feet (1.19 m³)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4/5 stars (for equipped models)
IIHS Small Overlap Front:
Not Recommended (based on similar era models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS)
Stability Control:
Optional Electronic Stability Program (ESP)
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side curtain airbags.
Seat Belts:
Three-point seat belts in all seating positions.
💡 Technology Features
Infotainment
Audio System:
Available premium audio systems (e.g., Boston Acoustics), CD player, AM/FM radio.
Navigation:
Optional GPS navigation system available on higher trim levels.
Driver Assistance
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack.
Comfort Features
Seating:
Available leather-trimmed seats, heated front seats, power adjustable driver's seat.
Climate Control:
Manual or dual-zone automatic climate control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 to 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specifics).
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).
Spark Plug Replacement:
4.7L V8: Every 100,000 miles. 5.7L HEMI V8: Every 100,000 miles (using specific HEMI spark plugs).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic or Conventional (check owner's manual for specific viscosity and API service classification).
Engine Oil Capacity:
4.7L: 6.0 Quarts (5.7 Liters). 5.7L HEMI: 7.0 Quarts (6.6 Liters).
Coolant Type:
Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, or equivalent meeting Chrysler MS-9769 specification.
Brake Fluid Type:
DOT 3
Known Issues
Common Issue 1:
Cooling system leaks (radiator, water pump, heater core) due to aging components.
Common Issue 2:
Power steering pump leaks or noise.
Common Issue 3:
ABS sensor failures leading to ABS warning lights.
Common Issue 4:
Hesitation or misfires on the 5.7L HEMI, potentially related to MDS (Multi-Displacement System) or valve spring issues.
Common Issue 5:
Interior trim rattles or squeaks common in large SUVs.
📚 Vehicle History
Brand Heritage
Brand Focus:
Dodge has a long history of producing trucks, SUVs, and performance vehicles.
Model Evolution
Generation Start:
First generation introduced in 1998.
Generation Second:
Second generation (DN) launched for the 2004 model year, featuring a significant redesign.
Key Design Changes 2004:
New styling, updated interior, introduction of the HEMI V8 option, improved chassis.
Production
Manufacturing Location:
Saltillo, Coahuila, Mexico
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the 2004 model are less common, the Durango was a strong contender in the family SUV market during its tenure, often praised for its towing capacity and available HEMI engine.
Ratings
Consumer Ratings:
Mixed to positive consumer reviews, with praise for performance and utility, but occasional critiques on fuel economy and reliability in certain areas.
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