2004 Dodge RAM 3500 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Dodge Model: RAM 3500 Year: 2004 Codes Platform: DR (Third Generation RAM) 👋 Introduction Market Position Segment: Heavy-duty pickup truck, designed for towing, hauling, and...

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标签: 2004 Cars Dodge Misc RAM 3500 Truck

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

RAM 3500

Year:

Codes

Platform:

DR (Third Generation RAM)

👋 Introduction

Market Position

Segment:

Heavy-duty pickup truck, designed for towing, hauling, and commercial use.

Competitive Analysis

Competitors:

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

Key Features

Design Philosophy:

Robust, durable construction, powerful engine options, and significant towing/hauling capabilities, reflecting a no-nonsense workhorse image.

Manual Advantage:

Officially licensed, comprehensive digital format for quick access and searchability, reducing reliance on outdated or incomplete printed materials.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Emissions

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Software (Digital)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full overhaul procedures for all gasoline and diesel engines, including timing, valvetrain, piston/ring installation, cylinder head assembly, and block machining specifications.

Engine Performance:

Fuel injection systems (MPI/CRDI), ignition systems, exhaust systems, turbocharger/supercharger (if applicable), and emissions control systems.

Transmission Manual:

Service and repair for manual transmissions, including clutch replacement, gear selection mechanisms, and gearbox overhaul.

Transmission Automatic:

Detailed diagnostic procedures, fluid capacities, torque converter operation, valve body service, and complete rebuild instructions for automatic transmissions.

Drivetrain:

Front and rear axle service, differential overhaul, driveshaft maintenance, U-joint replacement, and axle ratio specifications.

Suspension:

Front and rear suspension component replacement (ball joints, tie rods, control arms, springs, shock absorbers), alignment specifications, and wheel bearing service.

Steering:

Power steering system diagnostics, pump replacement, steering gear/rack and pinion service, and steering linkage repair.

Brakes:

Front and rear brake system service (disc and drum), ABS diagnostics and component replacement, brake fluid specifications, and bleeding procedures.

Electrical System:

Wiring diagrams for all circuits, starter, alternator, battery service, fuse and relay identification and testing, lighting systems, and instrument cluster diagnostics.

HVAC:

Air conditioning system service, refrigerant handling, heater core replacement, blower motor service, and climate control system diagnostics.

Bodywork:

Door panel removal, interior trim replacement, tailgate service, bumper repair, and basic body panel alignment.

Emissions:

Catalytic converter diagnosis, EGR system service, PCV system maintenance, and OBD-II diagnostic trouble code (DTC) interpretations.

Procedures Included

Maintenance:

Detailed scheduled maintenance procedures, including oil changes, filter replacements, spark plug replacement, brake fluid flushes, and cooling system service.

Troubleshooting:

Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common and complex issues across all vehicle systems.

Repair:

Step-by-step repair instructions with torque specifications, special tool requirements, and detailed diagrams for virtually every component and system.

Diagnostics:

Extensive diagnostic information, including DTC lookup, sensor data interpretation, and electronic control module (ECM) testing procedures.

Rebuilds:

Complete overhaul procedures for engines, transmissions, and differentials, including component specifications and tolerances.

Technical Depth

Depth:

Comprehensive, ranging from basic fluid level checks and tire pressure adjustments to advanced engine internal repairs, transmission overhauls, and complex electrical system diagnostics.

📊 Manual Specifications

File Format

File Type:

Proprietary software (likely executable with installer) or PDF documents within a browsable interface.

Print Quality

Quality:

High-resolution digital images, diagrams, and text; printable pages.

Binding Type

Binding:

N/A (Software)

Paper Type

Paper:

N/A (Software)

⚙️ Engine Specifications

Primary Engine

Base Engine:

8.0L Magnum V10 (8.0L 488 V10)

Optional Engine 1:

5.7L Magnum V8 (5.7L 345 V8)

Optional Engine 2:

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

Performance

8.0L V10 Horsepower:

305 hp @ 4400 rpm

8.0L V10 Torque:

455 lb-ft @ 3200 rpm

5.9L Cummins Horsepower:

305 hp @ 2800 rpm (for higher output versions)

5.9L Cummins Torque:

555 lb-ft @ 1400 rpm (for higher output versions)

Fuel System

Gasoline Injection:

Multi-port Fuel Injection (MPI)

Diesel Injection:

Common Rail Direct Injection (CRDI)

🔧 Transmission

Standard

Transmission Type:

6-speed manual (NV5600 for diesel, NV4500 for gas optional)

Optional

Transmission Type:

4-speed automatic (47RE for gasoline, 48RE for diesel)

Features

Transfer Case:

Part-time 4WD with electronic shift-on-the-fly (NV271D/NV273D)

📐 Dimensions

Exterior

Wheelbase:

Varies by cab and bed configuration (e.g., 134.1" for Regular Cab, 161.5" for Quad Cab)

Overall Length:

Varies by configuration (e.g., 227.8" for Regular Cab, 8' bed)

Weights

Curb Weight:

Approx. 6,500 - 7,500 lbs depending on configuration and engine

Gross Vehicle Weight Rating Gvwr:

10,500 - 11,500 lbs (depending on configuration)

Max Payload:

Up to 5,000 lbs (depending on configuration)

Max Towing Capacity:

Up to 12,000 - 13,000 lbs (depending on configuration and hitch type)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star (estimated for 4x2), 3-star (estimated for 4x4) – 2004 models

Active Features

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

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional cassette and premium audio systems. Basic infotainment features for the era.

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Trailer Brake Controller:

Optional integrated trailer brake controller available on some models.

Connectivity

Phone Integration:

No integrated Bluetooth or smartphone connectivity from the factory. Aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (refer to manual for specific recommendations based on oil type).

Oil Change Diesel:

Every 7,500 miles or 6 months (using synthetic oil). Cummins recommends 15,000 miles with specific oil and filter.

Transmission Fluid Change:

Automatic: 30,000-60,000 miles. Manual: Inspect at 30,000 miles, change as needed or at higher intervals.

Fuel Filter Diesel:

Every 15,000 miles ( Cummins 5.9L).

Fluid Specifications

Engine Oil Gasoline:

API SG/SH or higher; SAE 5W-30 or 10W-30 (refer to manual for exact viscosity based on temperature).

Engine Oil Diesel:

API CI-4 or CH-4; SAE 15W-40 (synthetic 5W-40 recommended for colder climates).

Transmission Fluid Automatic:

Chrysler ATF+4 (MS-9602).

Transmission Fluid Manual Nv5600:

GL-4 or GL-5 gear oil, SAE 75W-90.

Coolant:

Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, Blue.

Known Issues

Common Diesel Issue:

Injector pump (VP44) failures on early 5.9L Cummins, fuel heater issues, potential for head gasket leaks under extreme stress.

Common Gasoline Issue:

Spark plug misfires on V10, exhaust manifold cracks, occasional distributor issues.

Suspension Wear:

Ball joints, tie rod ends, and control arm bushings can wear prematurely under heavy use, especially in 4WD models.

Rear Main Seal Diesel:

Leaking rear main seal on 5.9L Cummins is a known issue, often exacerbated by heavy towing.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long-standing reputation for producing robust and capable trucks, dating back to the 1930s. The RAM nameplate was introduced in 1981.

Model Evolution

Third Generation:

The 2004 model year falls within the third generation of the Dodge RAM (2002-2008), characterized by a significant redesign featuring a more aggressive, bold styling and improved chassis.

Production

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Recognitions

Diesel Engine Reputation:

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