🏷️ Basic Information

Make:

Dodge

Model:

Ram 1500, Ram 2500, Ram 3500

Year:

2004

Vin Decoder Key:

1st digit: D (Dodge). 4th digit: W (Ram 1500), X (Ram 2500), Y (Ram 3500). 8th digit: Engine code (e.g., P for 4.7L V8, C for 5.9L Cummins Turbo Diesel).

Platform Code:

DR (Second Generation Ram Truck)

👋 Introduction

Market Segment:

Full-size pickup truck, positioned as a heavy-duty and capable workhorse, with significant presence in both commercial and consumer markets.

Key Competitors:

Ford F-Series (F-150, F-250, F-350), Chevrolet Silverado/GMC Sierra (1500, 2500HD, 3500HD), Toyota Tundra, Nissan Titan (though Titan debuted later).

Truck Features:

Robust construction, powerful engine options, high towing and payload capacities, distinct styling, available 4WD systems, various cab and bed configurations.

📋 Manual Details

Coverage:

Complete service, maintenance, and repair for all Dodge Ram 1500, 2500, and 3500 models for the 2004 model year.

Body And Chassis Coverage:

Detailed information on body structure, sheet metal repair, chassis components, frame specifications, and collision repair procedures.

Page Count:

Est. 1500-2500+ pages (typical for comprehensive factory-level manuals, specific count depends on publisher's aggregation)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF, typically) or Print

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, cooling system, exhaust system, ignition system, starting and charging system, powertrain control module (PCM) diagnostics, torque converter clutch (TCC) operation.

Transmission Drivetrain:

Manual transmissions (NV4500, G56), Automatic transmissions (48RE, 47RE, 42RE, 45RFE/545RFE), transfer cases (241DHD, 271D, 273D), front and rear axle assemblies, driveshafts, CV joints, universal joints.

Chassis Suspension Steering:

Front suspension (independent front suspension on 1500, solid front axle on 2500/3500), rear suspension (leaf springs, various axle configurations), steering system (power steering, steering gear, linkages), wheel alignment specifications.

Brakes:

Front disc brakes, rear disc or drum brakes (depending on model/application), anti-lock braking system (ABS) diagnostics and components, parking brake system, brake fluid specifications and bleeding procedures.

Electrical Electronics:

Battery, charging system, starting system, lighting systems (headlamps, tail lamps, interior), instrument cluster, body control module (BCM), Powertrain Control Module (PCM), fuse box locations and diagrams, relay functions, wiring diagrams for all major systems.

Body Interior HVAC:

Exterior body panels, doors, hood, tailgate, interior trim, seats, HVAC system (heater, air conditioning, blower motor, refrigerant handling, dash controls), power windows, power locks, mirrors, wipers, horn.

Maintenance:

Scheduled maintenance intervals, fluid checks and changes (engine oil, coolant, transmission fluid, brake fluid, power steering fluid), filter replacements (oil, air, fuel), lubrication points, tire rotation and balancing.

Troubleshooting:

Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting charts, electrical circuit testing, component testing procedures, common failure modes and solutions.

Repair Rebuild:

Step-by-step repair instructions for all major components, engine overhaul procedures, transmission rebuilds, brake system repairs, suspension and steering component replacement, electrical component repair/replacement, body panel repair, HVAC system component replacement.

Diagnostics:

Detailed diagnostic flowcharts for various systems, using scan tools, multimeter usage, component resistance and voltage checks, pressure testing (fuel, oil, coolant).

Engine Diagnostics:

Specific diagnostic procedures for engine performance issues, misfires, oil pressure problems, cooling system leaks, and emissions control systems.

Transmission Diagnostics:

Diagnostic procedures for automatic transmission shifting issues, torque converter clutch (TCC) engagement, manual transmission clutch and gear engagement problems.

Chassis Diagnostics:

Diagnosis of steering wander, suspension noise, brake pulsation, alignment issues, and driveline vibrations.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls, including electrical diagnostics and bodywork.

Wiring Diagrams:

Detailed, system-specific wiring diagrams for all electrical and electronic components, including fuse and relay assignments.

Torque Specifications:

Comprehensive torque specifications for all fasteners, including critical engine, transmission, suspension, and chassis components.

Diagnostic Trouble Codes:

Listing and explanation of all OBD-II diagnostic trouble codes (DTCs) relevant to the 2004 Ram, with diagnostic flowcharts for each.

Manual Content Detail:

Includes factory service procedures, specifications, technical service bulletins (TSBs) relevant to the model year, and detailed illustrations/exploded views.

📊 Manual Specifications

Digital Format Details:

Searchable PDF, often with hyperlinks for easy navigation. Printable pages.

Print Quality:

High-resolution images and diagrams (if applicable to digital version). Professional layout and clear typography.

Binding Type:

Spiral bound or perfect bound (for print versions) for lay-flat use in a workshop environment.

Paper Type:

Durable paper stock (e.g., 60 lb offset or higher) to withstand workshop conditions (for print versions).

⚙️ Engine Specifications

Engine Options:

4.7L Magnum V8 (P-Code), 5.9L Cummins Turbo Diesel I6 (ISB), 5.7L HEMI V8 (less common in 2004, more prevalent in later models, but some early integration may exist; predominantly 4.7L and 5.9L Diesel for this year's heavy applications).

4.7L V8 Performance:

Approx. 235-245 hp, 300-330 lb-ft torque. Sequential multi-port fuel injection (SMPI).

5.9L Cummins Performance:

Approx. 305-325 hp, 555-610 lb-ft torque. High-pressure common rail (HPCR) fuel system introduced on later models, 2004 might still feature earlier injection pump designs depending on build date/configuration. Rotary injection pump (VP44) on earlier 5.9L models, common rail on later 5.9L models.

Fuel Delivery 4.7L:

Sequential Multi-Port Fuel Injection (SMPI), Electric fuel pump.

Fuel Delivery 5.9L Cummins:

High-pressure common rail (HPCR) or Rotary Injection Pump (VE/VP series depending on specific variant and build date).

Engine Codes:

4.7L V8: P0300-P0308 (misfire codes), P0420 (catalyst system efficiency). 5.9L Cummins: Common codes related to injection system, turbocharger, EGR (if equipped), and emissions.

🔧 Transmission

Transmission 1500 Standard:

4-speed automatic (42RE, 45RFE/545RFE)

Transmission 2500 3500 Standard:

4-speed automatic (47RE, 48RE) or 5-speed manual (NV4500)

Transmission 1500 Optional:

5-speed manual (NV3500)

Transmission 2500 3500 Optional:

5-speed manual (G56 - successor to NV4500, introduced for 2005 model year, check for late 2004 builds if applicable but less common)

Transmission Features:

Electronically controlled automatic transmissions with overdrive, lock-up torque converter, power take-off (PTO) provision on some manual transmissions.

Transmission Fluid Capacity 48Re:

Approx. 11.9 US quarts (11.3 liters) with converter.

Transmission Fluid Capacity Nv4500:

Approx. 3.5 US quarts (3.3 liters).

📐 Dimensions

Wheelbase Options:

Varied by cab and bed configuration (e.g., 131.3" for standard cab short bed, 140.5" for crew cab short bed, 154.5" for long bed).

Overall Length:

Ranges from approx. 206" to 247" depending on configuration.

Curb Weight Range:

Approx. 4,500 lbs to 7,000+ lbs (heavily dependent on 4x4, engine, and configuration).

Gvwr Range:

Ranges from 6,050 lbs (1500) to 10,500+ lbs (3500 Heavy Duty).

🛡️ Safety Features

NHTSA Ratings Typical:

Frontal: 4/5 stars (driver/passenger). Side impact: Generally good, but less comprehensive data available for all configurations compared to modern standards. Rollover: 3/4 stars.

Active Safety:

Four-wheel disc brakes (standard on most models), optional Anti-lock Braking System (ABS).

Passive Safety:

Driver and front passenger airbags, three-point seat belts with pretensioners, crumple zones, reinforced safety cage.

💡 Technology Features

Infotainment Features:

Basic AM/FM radio, CD player (single or in-dash changer), cassette player (common in early models), optional premium audio systems, optional navigation (rare for the era).

Driver Assistance Features:

Cruise control, optional rear park assist (less common), ABS.

Connectivity Features:

Limited to basic auxiliary inputs for aftermarket devices (e.g., phone chargers), no integrated Bluetooth or USB connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations based on engine and oil spec).

Transmission Service Interval:

Automatic transmission fluid (ATF) change every 30,000-60,000 miles or 24-48 months, depending on towing and load usage. Manual transmission fluid inspection/change at similar intervals. Transfer case fluid: every 30,000-60,000 miles.

Engine Oil Spec 4.7L:

SAE 5W-30 API certified (e.g., Chrysler MS-6395 compliant). Check manual for specific viscosity and certification.

Engine Oil Spec 5.9L Cummins:

SAE 15W-40, API CI-4 or CH-4 rated heavy-duty diesel engine oil. For colder climates, SAE 5W-40 synthetic diesel oil is recommended. Check manual for exact specifications.

Coolant Spec:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, HOAT (Hybrid Organic Additive Technology) can be used as a substitute. Typically a 50/50 mix with distilled water. Color is usually orange or pink.

Transmission Fluid At:

ATF+4 (MS-9602) for 45RFE/545RFE. ATF+3 (MS-7176) or equivalent for 42RE, 47RE, 48RE. Diesel models may use different fluids. Crucial to verify with manual.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Common Issues 4.7L:

Plenum gasket leaks (causing oil consumption/misfires), ignition coil failure, dashboard cracking/warping, cooling fan clutch failure.

Common Issues 5.9L Cummins:

Lift pump failures (especially with VP44 pumps), injector failures, steering box wear, front-end steering/suspension wear (ball joints, tie rods), exhaust manifold cracking, grid heater issues.

Common Issues General:

Rust issues (especially around rear wheel wells and cab corners), HVAC blower motor resistor failure, door lock actuator failure, ABS sensor failures.

Oil Filter Part Number 4.7L:

e.g., Mopar: MO-090 / Fram: CH9999 / Wix: 57899 (Always verify exact part number for specific build date).

Oil Filter Part Number 5.9L Cummins:

e.g., Mopar: 3934400 / Fleetguard: LF9009 / Wix: 51410 (Always verify exact part number for specific build date).

📚 Vehicle History

Dodge Truck Heritage:

Dodge has a long-standing history in the pickup truck market, known for robust engineering and powerful engines, particularly with the Ram line.

Second Generation Ram:

The 2004 model is part of the second-generation Ram trucks (introduced in 1994), known for its distinctive 'big rig' styling. Significant updates occurred throughout this generation, including the introduction of the HEMI in later years and advancements in diesel technology.

Production Plant:

Primary production was in Warren, Michigan, and also Saltillo, Mexico.

🏆 Awards & Recognition

Model Year Awards:

While specific awards for the 2004 model year are less documented, the second-generation Ram truck series consistently received positive reviews for its styling, capability, and the powerful Cummins diesel option. It was a strong contender in its segment for many years.