🏷️ Basic Information

Make:

Dodge

Model:

Ram 3500

Year:

2004

Chassis Code:

DR

Product Type:

Service Repair Manual

👋 Introduction

Segment:

Heavy-Duty Pickup Truck

Purpose:

Designed for demanding work, towing, and hauling applications.

Competitors:

Ford Super Duty, Chevrolet Silverado HD, GMC Sierra HD.

Drivetrain Options:

Available in 2WD and 4WD configurations.

Cab Styles:

Regular Cab, Club Cab (Quad Cab), Crew Cab.

Bed Lengths:

8-foot bed standard.

Towing Hauling:

Class-leading towing and payload capacities for its era.

📋 Manual Details

General Coverage:

Comprehensive service and repair procedures for the 2004 Dodge Ram 3500 (DR chassis).

Estimated Pages:

1500+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train.

Engine Performance:

Fuel system, ignition system, emissions control, cooling system, lubrication system, turbocharger (if applicable).

Transmission Manual:

NV5600, G56 manual transmission service and repair.

Transmission Automatic:

48RE, NV4500 automatic transmission service and repair.

Drivetrain:

Front and rear axles, differentials, driveshafts, U-joints, transfer case (NV271/NV273).

Suspension:

Front and rear suspension systems, steering linkage, shocks, springs, ball joints, control arms.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, ABS, parking brake.

Steering:

Power steering system, steering column, steering gear/rack.

Electrical System:

Battery, charging system, starting system, ignition system, lighting, instrument cluster, wiring diagrams.

Body And Chassis:

Frame, body panels, doors, hood, tailgate, interior trim, seats, glass, bumpers.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components and service.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes.

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, tune-ups.

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for various systems and common issues.

Component Repair Overhaul:

Detailed instructions for repairing and overhauling major components and sub-assemblies.

Adjustments:

Valve adjustments, brake adjustments, steering adjustments.

Replacements:

Component replacement procedures for virtually all parts of the vehicle.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems.

Depth:

Comprehensive; covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed diagnostics and specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text

Quality:

High-resolution digital scans, clear text and images.

Binding:

N/A (Digital)

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Engine 1:

5.7L (345 ci) HEMI V8 (2500/3500)

Engine 1 Code:

1500/2500/3500 Series

Engine 2:

8.0L (488 ci) V10 (3500)

Engine 2 Code:

G/F

Engine 3:

5.9L (359 ci) Cummins Turbo Diesel I6 (3500)

Engine 3 Code:

ISB (Common Rail)

Hemi V8 Horsepower:

345 hp @ 4600 rpm

Hemi V8 Torque:

375 lb-ft @ 4000 rpm

V10 Horsepower:

325 hp @ 4000 rpm

V10 Torque:

450 lb-ft @ 3200 rpm

Cummins Hp:

305 hp @ 2900 rpm

Cummins Torque:

555 lb-ft @ 1400 rpm

Gasoline Injection:

Multi-point Fuel Injection (MPI)

Diesel Injection:

Common Rail Direct Injection (CRDI)

Fuel Type:

Unleaded gasoline (87 octane recommended), Diesel fuel

🔧 Transmission

Transmission 1:

48RE 4-speed Automatic (with 5.9L Cummins Diesel & 5.7L HEMI)

Transmission 2:

NV5600 6-speed Manual (with 8.0L V10 & 5.9L Cummins Diesel)

Transmission 3:

NV4500 5-speed Manual (earlier models, potentially carryover)

Overdrive:

All transmissions feature overdrive gears.

Transfer Case:

Electronic Shift Transfer Case (NV273) or Manual Shift Transfer Case (NV271).

📐 Dimensions

Wheelbase:

140.5 inches (Regular Cab), 160.5 inches (Quad Cab), 165.0 inches (Crew Cab)

Length:

Approx. 238.3 - 260.4 inches

Width:

Approx. 79.1 inches

Height:

Approx. 78.1 - 79.1 inches

Bed Length:

96.2 inches (standard 8-foot bed)

Curb Weight:

Approx. 6,000 - 7,500 lbs depending on configuration

Gvwr:

Up to 11,500 lbs

Gcwr:

Up to 23,000 lbs (Cummins Diesel)

🛡️ Safety Features

NHTSA Rollover Resistance:

3 Stars (typical for era)

ABS:

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

Towing Features:

Integrated trailer brake controller wiring (optional), tow/haul mode.

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point seat belts with pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional cassette player, upgraded Infinity sound system available.

Display:

Basic digital display for odometer, trip meter, and system warnings.

Cruise Control:

Standard cruise control.

Trailer Wiring:

Standard trailer wiring harness for trailer lights and brake signals (7-pin connector often standard).

🔧 Maintenance

Oil Change Gasoline:

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

Oil Change Diesel:

Every 7,500 miles or 6 months for conventional oil; 15,000 miles or 12 months for synthetic oil (refer to manual).

Fuel Filter Diesel:

Every 15,000 - 30,000 miles (depending on fuel quality and usage).

Air Filter:

Inspect every 15,000 miles, replace as needed.

Transmission Fluid Automatic:

Inspect fluid level periodically, change every 30,000 - 60,000 miles depending on load and conditions.

Transmission Fluid Manual:

Inspect and change every 60,000 - 100,000 miles.

Engine Oil Gasoline:

SAE 5W-30 or 5W-40 (synthetic blend recommended for towing/heavy use).

Engine Oil Diesel:

API CJ-4 or CK-4 synthetic or synthetic blend diesel engine oil (e.g., 15W-40, 5W-40).

Coolant:

Mopar OAT (Orange) Antifreeze/Coolant, 50/50 mix with distilled water.

Transmission Fluid 48Re:

ATF+4 (MS-9602 compliant).

Transmission Fluid Nv5600:

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

Cummins Injection Pump:

Potential failure of the VP44 injection pump (earlier 2001-2002 models, less common on 2004 but still possible).

Transmission Hard Shifts:

48RE transmission can sometimes exhibit hard shifting due to worn solenoids or valve body issues.

Front End Components:

Wear on ball joints, tie rods, and steering components due to the weight and typical use of heavy-duty trucks.

Exhaust Manifold Cracks:

Cracked exhaust manifolds, particularly on the 5.9L Cummins, can be an issue due to thermal cycling.

📚 Vehicle History

Brand History:

Dodge has a long-standing reputation for producing robust trucks, evolving from the original Dodge Power Wagon to the modern Ram trucks.

Third Generation Ram:

The 2004 model is part of the third generation of Ram trucks (2002-2008), which saw significant redesigns in styling, chassis, and powertrains, including the introduction of the HEMI V8 and the common-rail Cummins.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Engine Awards Cummins:

The 5.9L Cummins Turbo Diesel engine is widely recognized for its durability and longevity.

Tow Haul Ratings:

Consistently rated highly for towing and hauling capabilities within its class.