2004 DODGE RAM 3500 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Year: 2004 Codes Chassis Code: DR (Third Generation Ram Pickup) 👋 Introduction Market Position Vehicle Segment: Heavy-duty pickup truck, designed for...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 3500

Year:

Codes

Chassis Code:

DR (Third Generation Ram Pickup)

👋 Introduction

Market Position

Vehicle Segment:

Heavy-duty pickup truck, designed for towing, hauling, and demanding work applications.

Competitive Analysis

Competitors:

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

Key Features

Powertrain Options:

Renowned for robust engine options, including the powerful Cummins turbodiesel and strong HEMI V8s.

Design:

Distinctive Dodge Ram styling with a prominent grille and robust chassis construction.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed overhaul, diagnostics, lubrication, cooling, fuel, ignition, emissions control systems.

Transmission:

Service and repair for automatic (e.g., 48RE, 47RE) and manual transmissions (e.g., NV5600), transfer case operation.

Brakes:

Hydraulic system, ABS, disc brake service, drum brake service (rear), parking brake system.

Suspension Steering:

Front and rear suspension components, steering gear, power steering system, wheel alignment specifications.

Electrical:

Complete wiring diagrams, starter, alternator, battery, lighting, instrumentation, body electrical components, trailer wiring.

Body Chassis:

Frame repair, body panel replacement, doors, hood, tailgate, interior trim, glass, bumpers.

HVAC:

Air conditioning system service, heater core, blower motor, climate control.

Exhaust:

Exhaust system components, catalytic converter, muffler.

Procedures Included

Maintenance:

Oil change intervals, filter replacement (oil, fuel, air), spark plug replacement, fluid checks and changes.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), component testing procedures.

Repair:

Step-by-step repair instructions for all major vehicle systems, including engine rebuild, transmission overhaul, brake caliper replacement.

Troubleshooting:

Detailed troubleshooting flowcharts for common and uncommon problems, electrical system diagnostics.

Technical Depth

Level Of Detail:

Comprehensive, suitable for professional technicians and advanced DIY mechanics. Includes torque specifications, clearances, and detailed diagnostic procedures.

Content Scope:

Covers routine maintenance, minor repairs, major overhauls, electrical diagnostics, and component replacement.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval.

Print Quality:

High-resolution scans of original documentation, suitable for printing.

Binding Type

Binding:

N/A (PDF format)

Paper Type

Paper Type:

N/A (PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

5.7L HEMI Magnum V8, 5.9L Cummins ISB Turbo Diesel I6, 8.3L V10 Viper.

5.7L Hemi V8 Displacement:

5.7 Liters (345 cu. in.)

5.7L Hemi V8 Horsepower:

Approximately 345 hp @ 5400 rpm

5.7L Hemi V8 Torque:

Approximately 375 lb-ft @ 4200 rpm

5.9L Cummins Displacement:

5.9 Liters (359 cu. in.)

5.9L Cummins Horsepower:

Approximately 305 hp @ 2800 rpm (with higher output variants available)

5.9L Cummins Torque:

Approximately 555 lb-ft @ 1400 rpm (with higher output variants available)

Fuel System

Fuel Delivery Gas:

Sequential Electronic Fuel Injection (SEFI)

Fuel Delivery Diesel:

High-pressure common rail injection system (for 5.9L Cummins)

🔧 Transmission

Standard

Standard Transmission:

May vary by specific configuration, often 6-speed manual (NV5600) for diesel models.

Optional

Optional Transmission:

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

Features

Transmission Cooling:

Integrated transmission fluid coolers for heavy-duty applications.

Transfer Case:

Part-time 4WD system with electronic shift-on-the-fly (ESOF) or manual transfer case options.

📐 Dimensions

Exterior

Wheelbase:

Varies by configuration (e.g., 134.1" for standard cab, 160.3" for crew cab long bed)

Overall Length:

Varies by configuration (e.g., 229.7" for standard cab)

Overall Width:

Approximately 79.7"

Overall Height:

Approximately 77.7"

Cargo

Bed Length Options:

8-foot "Long Bed"

Weights

Curb Weight:

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

Gross Vehicle Weight Rating:

Up to 11,500 lbs

Max Towing Capacity:

Up to 13,000 lbs (properly equipped)

Max Payload Capacity:

Up to 4,800 lbs (properly equipped)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Not directly rated for heavy-duty trucks in the same manner as light-duty vehicles; emphasis on robust construction.

IIHS Crash Test:

Focus on structural integrity for heavy-duty use; specific ratings may vary.

Active Features

Anti-lock Braking System (ABS) standard on all wheels, often with trailer brake controller integration.

Traction Control:

Traction control systems available on some models.

Passive Features

Airbags:

Driver and passenger airbags.

Seatbelts:

Three-point seat belts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD audio systems, with available premium sound options. Cassette player still common in base models.

Navigation:

Aftermarket navigation systems or basic trip computers were common; factory navigation was less prevalent.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Trailer Lights Interface:

Integrated wiring harness for trailer lights and electric trailer brake controllers.

Powertrain Tech

Engine Control Module:

ECM (Engine Control Module) manages fuel injection, ignition timing, and emissions for gasoline engines. Similar ECUs for diesel.

🔧 Maintenance

Service Intervals

Oil Change Interval Gas:

Typically 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type.

Oil Change Interval Diesel:

Typically 7,500 miles or 6 months for 5.9L Cummins, using diesel-specific oil.

Fuel Filter Replacement Diesel:

Recommended every 15,000-30,000 miles for the 5.9L Cummins.

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, depending on towing/hauling usage. Manual transmission fluid service intervals are longer.

Fluid Specifications

Engine Oil Gas Viscosity:

SAE 5W-30 or 5W-40 (check owner's manual for specific recommendations).

Engine Oil Diesel Viscosity:

API CJ-4 or CK-4 rated 15W-40 or 5W-40 diesel engine oil (e.g., Shell Rotella T6).

Coolant Type:

HOAT (Hybrid Organic Acid Technology) antifreeze, typically Mopar OAT or equivalent.

Transmission Fluid Automatic:

ATF+4 (Automatic Transmission Fluid) for 47RE/48RE transmissions.

Transmission Fluid Manual:

GL-3 or GL-4 rated gear oil for NV5600 (e.g., Red Line MTL).

Known Issues

5.9L Cummins Injector Problems:

Potential issues with injector failure or VP44 injection pump failure on earlier models, though 2004 models generally have improved reliability.

Automatic Transmission Overheating:

47RE/48RE transmissions can be prone to overheating under heavy towing without auxiliary coolers.

Front End Components:

Wear on ball joints, tie rod ends, and steering linkage due to the weight and stresses of a heavy-duty truck.

Body Rust:

Common for trucks of this era, particularly in areas with road salt exposure; check frame rails and wheel wells.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing rugged and capable trucks since the 1930s.

Model Evolution

Ram Generation:

This 2004 model belongs to the third generation (2002-2008) of the Dodge Ram pickup truck, characterized by its significant redesign.

Heavy Duty Focus:

The Ram 3500 specifically targets the heavy-duty market, offering enhanced towing and payload capabilities over its 1500 and 2500 counterparts.

Production

Manufacturing Location:

Saltillo Truck Plant, Saltillo, Coahuila, Mexico; Warren Truck Assembly Plant, Warren, Michigan, USA.

🏆 Awards & Recognition

Recognitions

Segment Popularity:

The 5.9L Cummins-equipped Ram trucks were highly regarded for their durability and towing prowess, earning a loyal following.

Engine Awards:

The Cummins turbodiesel engine is consistently praised for its longevity and performance in the trucking industry.

Ratings

Consumer Reports Reliability:

Reliability ratings vary by powertrain and specific components; the Cummins diesel generally scores well.