🏷️ Basic Information

Make:

Dodge

Model:

RAM 2500

Year:

2004

Product Type:

Service & Repair Manual Software

Licensing:

Officially Licensed

👋 Introduction

Segment:

Heavy-duty pickup truck.

Target Audience:

Owners requiring in-depth knowledge for maintenance and repair, professional mechanics, fleet managers.

Competitors:

Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD.

Advantage:

Officially licensed, providing accurate and complete factory information. Digital format offers searchability and accessibility.

📋 Manual Details

Overall Coverage:

Comprehensive repair, maintenance, diagnostics, and troubleshooting for all systems.

Estimated Pages:

Likely exceeds 1500 pages (typical for comprehensive service manuals of this era).

Type:

Service and Repair Manual

Language:

English

Format:

Software (Digital Download - PDF or proprietary executable)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, and torque specifications for all components (e.g., pistons, rings, bearings, crankshaft, camshaft, cylinder head).

Engine Performance:

Fuel system, ignition system, exhaust system, cooling system, lubrication system, emissions control systems.

Transmission Manual:

Service and repair procedures for manual transmissions (if applicable to specific models).

Transmission Automatic:

Service and repair procedures for automatic transmissions, including torque converter, valve body, clutch packs, and electronic controls.

Drivetrain:

Four-wheel drive system (NV271, NV273 transfer cases), axle assemblies, propeller shafts, CV joints, wheel bearings.

Brakes:

Hydraulic brake system, ABS (Anti-lock Braking System), brake calipers, rotors, pads, lines, master cylinder, power booster.

Steering:

Power steering system, steering gear, steering column, linkages, tie rods, power steering pump, fluid.

Suspension:

Front suspension (independent suspension components, control arms, ball joints, shocks, struts), rear suspension (leaf springs, shocks), alignment specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems, power windows, power locks, mirrors, wipers, horns.

Body And Chassis:

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

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, refrigerant, blower motor, climate controls.

Restraint Systems:

Airbag system, seat belts, SRS (Supplemental Restraint System) components and diagnostics.

Diagnostics:

Diagnostic Trouble Codes (DTCs) for all major systems, scan tool procedures, sensor testing, component testing.

Preventive Maintenance:

Scheduled maintenance intervals, fluid checks and changes, filter replacements, tire rotation, brake inspection.

Troubleshooting:

Step-by-step diagnostic procedures for identifying and resolving common and uncommon faults.

Repair And Replacement:

Detailed instructions for component removal, installation, and adjustment for all vehicle systems.

Overhaul:

Complete engine and transmission overhaul procedures with detailed component specifications.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all circuits, including power distribution, grounds, and component connections.

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data.

Depth:

Expert-level, suitable for professional technicians and advanced DIYers. Covers everything from basic fluid changes to complete engine and transmission rebuilds, as well as in-depth electrical diagnostics.

📊 Manual Specifications

Digital Format:

Typically PDF or a proprietary executable program with searchable content and interactive diagrams.

Printability:

High-resolution content suitable for printing individual sections or the entire manual.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Options:

5.7L HEMI V8 (345 cid), 8.0L Magnum V10 (488 cid), 5.9L Cummins Turbo Diesel I6 (359 cid).

Engine Code 5 7L:

MAGNUM 5.7L V8

Engine Code 8 0L:

MAGNUM 8.0L V10

Engine Code 5 9L Cummins:

5.9L 24V CUMMINS TURBO DIESEL

Horsepower 5 7L:

325 hp @ 4800 rpm

Torque 5 7L:

375 lb-ft @ 4000 rpm

Horsepower 8 0L:

305 hp @ 4200 rpm

Torque 8 0L:

450 lb-ft @ 3200 rpm

Horsepower 5 9L Cummins:

305 hp @ 2900 rpm

Torque 5 9L Cummins:

555 lb-ft @ 1400 rpm

Fuel Delivery Gas:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Delivery Diesel:

High-pressure Common Rail (HPCR) fuel injection system

Block Material 5 7L 8 0L:

Cast Iron

Head Material 5 7L 8 0L:

Aluminum (5.7L HEMI), Cast Iron (8.0L Magnum)

Block Material 5 9L Cummins:

Cast Iron

Head Material 5 9L Cummins:

Cast Iron

🔧 Transmission

Standard Transmission Gas:

NV4500 5-speed Manual Transmission (typically with the 5.9L Cummins Diesel, and optional on gasoline engines)

Optional Transmission Gas:

48RE 4-speed Automatic Transmission (with OD)

Optional Transmission Diesel:

NV4500 5-speed Manual Transmission; 48RE 4-speed Automatic Transmission (with OD)

Overdrive Gear:

All automatic transmissions and the NV4500 manual feature an overdrive gear for improved fuel economy at highway speeds.

Transfer Case:

NV271 (Manual Shift) or NV273 (Electronic Shift-on-the-Fly) for 4x4 models.

📐 Dimensions

Wheelbase Regular Cab:

134.1 inches

Wheelbase Extended Cab:

140.5 inches

Wheelbase Crew Cab:

160.5 inches

Bed Length Standard:

6.3 feet (75.9 inches)

Bed Length Long:

8.0 feet (96.3 inches)

Gvwr Gas:

Up to 9,750 lbs

Gvwr Diesel:

Up to 10,000 lbs

Curb Weight:

Varies by configuration, typically 6,000 - 7,500 lbs.

🛡️ Safety Features

NHTSA Rollover Resistance Rating:

4 out of 5 stars (for 4x2 models), 3 out of 5 stars (for 4x4 models) - Note: Ratings can vary slightly by specific configuration and test year.

ABS:

Standard 4-wheel Anti-lock Braking System (ABS).

Airbags:

Standard driver and passenger front airbags. Side airbags may be optional depending on trim.

Seatbelts:

Height-adjustable front seat belts with pretensioners.

💡 Technology Features

Audio System:

Base AM/FM stereo with CD player and optional Infinity premium audio system. Cassette player was still available on some models.

Climate Control:

Manual or optional dual-zone automatic climate control.

Cruise Control:

Standard on most trims.

Power Outlets:

12V auxiliary power outlets in the cabin.

🔧 Maintenance

Oil Change Gas:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (consult manual for specific recommendation).

Oil Change Diesel:

Every 7,500 miles or 6 months (synthetic oil recommended for optimal performance and longevity).

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed. Critical for diesel engine performance.

Fuel Filter Replacement Diesel:

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

Transmission Fluid Service:

Automatic: 30,000-60,000 miles. Manual: Inspect regularly, fluid change typically recommended at higher mileage (e.g., 100,000 miles) or if experiencing issues.

Engine Oil 5 7L 8 0L:

API SG, SH, SJ, or SL certified SAE 5W-30 or 5W-40 (refer to manual for specific viscosity based on temperature).

Engine Oil 5 9L Cummins:

API CJ-4 or CK-4 certified SAE 15W-40 (synthetic 5W-40 recommended for cold weather).

Coolant:

Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically a 50/50 mix with distilled water. Extended life coolant may be used if compatible.

Transmission Fluid Automatic:

ATF+4 (Automatic Transmission Fluid Type 95)

Transmission Fluid Manual Nv4500:

GL-3 or GL-4 rated gear oil, typically SAE 75W-90 or 80W-90.

Power Steering Fluid:

Chrysler Type MS-5937 or equivalent.

Cummins Injectors:

Early 5.9L common rail models can experience injector issues, often related to fuel contamination or wear.

Transmission 48Re:

The 48RE can sometimes develop issues with the torque converter clutch or solenoid pack, particularly under heavy use.

Steering Components:

Ball joints, tie rod ends, and steering box can wear over time due to the weight and usage typical for a heavy-duty truck.

Rust:

Corrosion on body panels, frame, and exhaust system can be an issue in areas with road salt.

📚 Vehicle History

Dodge Trucks:

Dodge has a long and storied history in the truck market, with the RAM nameplate becoming synonymous with capability and durability.

Third Generation Ram:

The 2004 model year falls within the third generation of the Dodge Ram (1994-2001 and 2002-2008). This generation marked a significant redesign with a more aggressive, muscular styling and improved chassis dynamics.

Manufacturing Plant:

Saltillo Truck Assembly Plant, Saltillo, Mexico; St. Louis Assembly Plant, Fenton, Missouri (closed 2009).

🏆 Awards & Recognition

Reputation:

The 5.9L Cummins Turbo Diesel engine is highly regarded for its reliability and durability, often considered one of the best diesel engines of its era.