2004 Dodge Ram Truck 1500 2500 3500 Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 1500, 2500, 3500 Year: 2004 Codes Chassis Code: DR (Third Generation Dodge Ram) 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY mechanics, and fleet maintenance personnel working on 2004 Dodge Ram trucks. Competitive Analysis Manual Type Advantage: Directly sourced or replicating factory service manual content, offering unparalleled accuracy and detail compared to generic Haynes or Chilton manuals for this era. Key Features Completeness: Covers all aspects of vehicle maintenance, diagnosis, and repair, from routine service to major component overhauls and electrical diagnostics. Diagnostic Focus: Extensive troubleshooting procedures, including symptom charts and diagnostic flowcharts, essential for complex electronic and mechanical issues. Technical Data: Includes all critical technical specifications, torque values, fluid capacities, clearances, and diagnostic trouble codes (DTCs). 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all listed Dodge Ram models (1500, 2500, 3500) Page Count Estimated Pages: Over 1500 Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, starting system, charging system, transmission (automatic and manual), transfer case, driveline components. Chassis: Suspension (front and rear), steering system, brakes (hydraulic, ABS, parking), wheels and tires, frame and bumpers. Body: Body and frame, exterior components, interior trim, seating systems, power accessories (windows, locks, mirrors, seats), HVAC system, lamps, wipers and washers, horn, speed control, audio systems. Electrical: Battery, charging system, starting system, instrument panel systems, power distribution, wiring diagrams, passive restraint systems, electrically heated systems, vehicle theft/security systems, chime/buzzer warning systems, overhead console systems. Emissions: Emission control systems diagnostics and repair. Procedures Included Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, electrical system diagnostics, powertrain diagnostics. Maintenance Procedures: Lubrication, fluid changes, filter replacements, scheduled maintenance intervals. Repair Procedures: Step-by-step instructions for component removal, installation, adjustment, and overhaul. System Overhauls: Detailed procedures for major component rebuilding (e.g., engine, transmission, differentials). Technical Depth Depth Of Information: Extremely detailed, covering factory-level repair procedures, specifications, tolerances, and diagnostic information. Wiring Diagrams Quality: Comprehensive, illustrating all major electrical circuits and components for accurate troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text for efficient information retrieval Print Quality Print Readability: Designed for clear print output with professional formatting Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 4.7L Magnum V8 (P-Code), 5.7L HEMI V8 (8-Code), 3.7L Magnum V6 (E-Code), 5.9L Cummins Turbo Diesel I6 (ISB) Performance 4.7L Magnum V8 (Approximate): Horsepower: 235 hp @ 4,500 rpm, Torque: 305 lb-ft @ 3,200 rpm 5.7L Hemi V8 (Approximate): Horsepower: 345 hp @ 5,000 rpm, Torque: 375 lb-ft @ 4,000 rpm 3.7L Magnum V6 (Approximate): Horsepower: 215 hp @ 5,200 rpm, Torque: 235 lb-ft @ 4,000 rpm 5.9L Cummins Turbo Diesel (Approximate): Horsepower: 305 hp @ 2,900 rpm, Torque: 555 lb-ft @ 1,700 rpm Fuel System Fuel Delivery Gas: Sequential Electronic Fuel Injection (SEFI) Fuel Delivery Diesel: Common Rail Fuel Injection (CRFI) Engine Management ECU Type: Various Chrysler NGC (Next Generation Controller) or Cummins ECM Engine Cooling Cooling System Type: Pressurized Liquid Cooling System 🔧 Transmission Standard Transmission Options: 4-speed Automatic (42RLE, 48RE), 5-speed Manual (NV3500, G56) Optional Heavy Duty Transmission: 48RE Automatic (Heavy Duty, Diesel), G56 6-speed Manual (Diesel) Features Transfer Case: Command-Trac (NV244 or NV246) or Power-Trac (NV273) manual shift 4WD systems Fluid Specs Automatic Transmission Fluid: ATF+4 (Mopar) Manual Transmission Fluid: Refer to manual, typically GL-4 or GL-5 gear oil (specific viscosity varies by transmission) Transfer Case Fluid: Refer to manual, typically Mopar ATF+4 or specific gear oil 📐 Dimensions Exterior Body Styles: Regular Cab, Extended Cab (Club Cab), Crew Cab Wheelbase Options: Various, including 134.0", 140.5", 147.4", 160.5", 165.5" inches depending on cab and bed configuration. Bed Lengths: Standard (approx. 6.3 ft), Long (approx. 8 ft) Weights Gross Vehicle Weight Rating: Ranges from approximately 6,000 lbs (1500) to over 11,000 lbs (3500 HD Diesel). Curb Weight: Varies significantly by configuration, typically 4,500 - 7,500 lbs. Towing Capacity: Up to 10,000+ lbs depending on model, configuration, and drivetrain. Payload Capacity: Up to 5,000+ lbs depending on model, configuration, and drivetrain. 🛡️ Safety Features Ratings NHTSA Crash Test: Varies by year and specific test; generally good for its class at the time but pre-dates many modern safety standards. Manual will cover passive restraint system details. Active Features ABS: Standard Anti-lock Braking System (ABS) on most models. Traction Control: Available on some models and configurations. Passive Features Airbags: Driver and front passenger airbags standard. Seat Belts: Three-point seat belts with pretensioners. Child Anchors: LATCH (Lower Anchors and Tethers for Children) system provisions. 💡 Technology Features Infotainment Audio Systems: Factory AM/FM/CD players, optional cassette, premium sound systems, SiriusXM satellite radio readiness. Navigation: Optional factory navigation system on higher trim levels....
Professional technicians, experienced DIY mechanics, and fleet maintenance personnel working on 2004 Dodge Ram trucks.
Competitive Analysis
Manual Type Advantage:
Directly sourced or replicating factory service manual content, offering unparalleled accuracy and detail compared to generic Haynes or Chilton manuals for this era.
Key Features
Completeness:
Covers all aspects of vehicle maintenance, diagnosis, and repair, from routine service to major component overhauls and electrical diagnostics.
Diagnostic Focus:
Extensive troubleshooting procedures, including symptom charts and diagnostic flowcharts, essential for complex electronic and mechanical issues.
Technical Data:
Includes all critical technical specifications, torque values, fluid capacities, clearances, and diagnostic trouble codes (DTCs).
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all listed Dodge Ram models (1500, 2500, 3500)
Command-Trac (NV244 or NV246) or Power-Trac (NV273) manual shift 4WD systems
Fluid Specs
Automatic Transmission Fluid:
ATF+4 (Mopar)
Manual Transmission Fluid:
Refer to manual, typically GL-4 or GL-5 gear oil (specific viscosity varies by transmission)
Transfer Case Fluid:
Refer to manual, typically Mopar ATF+4 or specific gear oil
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Extended Cab (Club Cab), Crew Cab
Wheelbase Options:
Various, including 134.0", 140.5", 147.4", 160.5", 165.5" inches depending on cab and bed configuration.
Bed Lengths:
Standard (approx. 6.3 ft), Long (approx. 8 ft)
Weights
Gross Vehicle Weight Rating:
Ranges from approximately 6,000 lbs (1500) to over 11,000 lbs (3500 HD Diesel).
Curb Weight:
Varies significantly by configuration, typically 4,500 - 7,500 lbs.
Towing Capacity:
Up to 10,000+ lbs depending on model, configuration, and drivetrain.
Payload Capacity:
Up to 5,000+ lbs depending on model, configuration, and drivetrain.
🛡️ Safety Features
Ratings
NHTSA Crash Test:
Varies by year and specific test; generally good for its class at the time but pre-dates many modern safety standards. Manual will cover passive restraint system details.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Available on some models and configurations.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
Three-point seat belts with pretensioners.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system provisions.
Optional factory navigation system on higher trim levels.
Driver Assistance
Cruise Control:
Standard speed control system.
Parking Assistance:
Rear parking assist sensors optional on some models.
Connectivity
Remote Keyless Entry:
Available on most models.
Anti Theft:
Factory immobilizer system and optional alarm system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 3-6 months, depending on engine, oil type (conventional vs. synthetic), and driving conditions (severe vs. normal). Manual provides detailed recommendations.
Filter Replacement:
Engine oil filter, air filter, fuel filter (diesel), cabin air filter replacement recommendations based on mileage and time.
Tire Rotation:
Typically every 5,000-7,500 miles.
Brake Maintenance:
Inspection of pads, rotors, fluid levels, and lines at regular intervals, usually tied to tire rotations or service checks.
Fluid Specifications
Engine Oil Gas V8:
SAE 5W-20 or 5W-30 (synthetic blend or full synthetic recommended), API Certified
Engine Oil Diesel:
API CJ-4 or newer, SAE 15W-40 (synthetic recommended for colder climates)
Coolant:
Chrysler/Mopar OAT (Organic Additive Technology) or HOAT (Hybrid OAT) coolant, typically orange or pink color, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 (check specific recommendation for ABS systems)
Known Issues
Common Issues Gas Engines:
Head gasket issues (especially on early 4.7L), plenum gasket leaks, intake manifold gasket leaks, spark plug ejection (HEMI), camshaft wear.
Common Issues Diesel Engines:
VP44 injection pump failures (prior to common rail), grid heater issues, injector problems, turbocharger issues, clutch wear (manual).
Common Issues Suspension Steering:
Ball joint wear, tie rod end wear, steering stabilizer issues, front end wobble (death wobble on heavily modified trucks).
Common Issues Electrical:
Instrument cluster failures, TIPM (Totally Integrated Power Module) issues, failing sensors, power window motor failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram line being a cornerstone since its introduction.
Model Evolution
Third Generation Ram:
The 2004 model year is part of the third generation (2002-2008), which introduced a significant redesign with a larger, more muscular appearance, improved aerodynamics, and updated powertrains including the introduction of the HEMI V8.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA.
Sales Performance:
The Dodge Ram has consistently been one of the best-selling full-size pickup trucks in North America.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific 2004 awards vary, the Dodge Ram platform has historically received numerous 'Truck of the Year' accolades from various automotive publications over its generations.
Ratings
Consumer Satisfaction:
Consumer satisfaction ratings vary, but the Ram trucks of this era are often praised for their styling, towing capacity, and V8 engine performance, particularly the HEMI.
Certifications
Emissions Compliance:
All models are designed to meet the relevant EPA and CARB emissions standards for the 2004 model year.