Dodge Ram 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Year: 2004 Model Code: DR/DH/D1 Platform: Third Generation Ram (2002-2008) 👋 Introduction Market Position Segment: Full-size pickup truck. Key Strengths: Robust construction,...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Model Code:

DR/DH/D1

Platform:

Third Generation Ram (2002-2008)

👋 Introduction

Market Position

Segment:

Full-size pickup truck.

Key Strengths:

Robust construction, powerful engine options (including HEMI and Cummins), towing capacity, traditional truck utility.

Competitive Analysis

Competitors:

Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra.

Key Features Vehicle

Design:

Bold styling, large grille, aggressive stance, distinctive Ram's head emblem.

Key Features Manual

Utility:

Essential for accurate diagnostics, efficient repairs, and preventative maintenance.

📋 Manual Details

Coverage Areas

Title:

Dodge Ram 2004 Factory Service Repair Manual

Description:

Comprehensive repair and maintenance information for Dodge Ram 2004 models.

Page Count

Estimated Pages:

Over 1500

Manual Type

Type:

Factory Service Manual (FSM)

Intended Audience:

Professional mechanics and experienced DIY enthusiasts.

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

All gasoline and diesel engines (e.g., 3.7L Magnum, 4.7L Magnum, 5.7L HEMI, 5.9L Cummins Turbo Diesel).

Transmission:

Automatic transmissions (e.g., 42RLE, 48RE, 47RE) and manual transmissions (e.g., NV3500, NV4500).

Drivetrain:

Front and rear axles, differentials, transfer cases, driveshafts, CV joints.

Suspension:

Front and rear suspension, springs, shocks/struts, control arms, steering components.

Brakes:

Front and rear disc brakes, anti-lock braking system (ABS), parking brake.

Steering:

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

Electrical:

Battery, charging system, starting system, ignition system, lighting, body electrical, instrument cluster, Powertrain Control Module (PCM).

HVAC:

Heating, ventilation, and air conditioning system components and operation.

Body:

Body panels, doors, windows, locks, mirrors, interior trim, bumpers, chassis components.

Fuel:

Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emission control (EVAP) system.

Exhaust:

Exhaust manifolds, catalytic converter, mufflers, exhaust pipes.

Cooling:

Radiator, water pump, thermostat, cooling fan, coolant hoses.

Emissions:

Diagnosis and repair of emissions control systems.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes.

Troubleshooting:

Diagnostic procedures, symptom charts, fault code interpretation.

Repair:

Step-by-step repair instructions for all major components and systems.

Diagnostics:

On-Board Diagnostics (OBD-II) system testing and analysis.

Adjustments:

Calibration and adjustment of various systems.

Disassembly Assembly:

Complete procedures for component removal and installation.

Wiring Diagrams:

Detailed electrical schematics for all circuits.

Specifications:

Torque specifications, clearances, tolerances, and other critical measurements.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complex component overhauls and diagnostics.

📊 Manual Specifications

File Format

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Options:

3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 5.9L Cummins I6 Turbo Diesel.

Performance

3.7L Magnum V6 Hp:

215 hp @ 5200 rpm

3.7L Magnum V6 Torque:

235 lb-ft @ 4000 rpm

4.7L Magnum V8 Hp:

235 hp @ 4800 rpm (early models), 260 hp @ 5200 rpm (later models)

4.7L Magnum V8 Torque:

295 lb-ft @ 3200 rpm (early models), 325 lb-ft @ 3600 rpm (later models)

5.7L Hemi V8 Hp:

345 hp @ 5000 rpm

5.7L Hemi V8 Torque:

375 lb-ft @ 4000 rpm

5.9L Cummins I6 Turbo Diesel Hp:

305 hp @ 2900 rpm

5.9L Cummins I6 Turbo Diesel Torque:

555 lb-ft @ 1400 rpm

Fuel System

Induction Gasoline:

Sequential Multi-Port Fuel Injection (MPI)

Induction Diesel:

High-pressure common rail fuel injection system

Fuel Type:

Unleaded gasoline (87 octane recommended), Diesel fuel.

Engine Management

Powertrain Control Module (PCM) / Engine Control Unit (ECU)

🔧 Transmission

Standard

Automatic Standard:

42RLE 4-speed automatic (with 3.7L V6 and 4.7L V8)

Optional

Automatic Optional Heavy Duty:

48RE 4-speed automatic (with 5.7L HEMI and 5.9L Cummins)

Manual Standard:

NV3500 5-speed manual (with 3.7L V6)

Manual Optional Heavy Duty:

NV4500 5-speed manual (with 5.9L Cummins)

Features

Overdrive:

All automatic transmissions feature overdrive.

4X4 System:

Electronic shift transfer case (2WD, 4WD High, 4WD Low) on most models.

📐 Dimensions

Exterior

Body Styles:

Regular Cab, Club Cab (extended cab), Mega Cab (crew cab).

Bed Lengths:

6.3 ft, 8.0 ft

Weights

Gvwr Range:

6,500 lbs to 10,500 lbs (depending on configuration)

Curb Weight Range:

Approx. 4,500 lbs to 6,500 lbs

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

NHTSA Frontal Passenger:

IIHS Frontal Offset:

Acceptable

Active Features

Standard Anti-lock Braking System (ABS).

Traction Control:

Available traction control system.

Passive Features

Airbags:

Front airbags for driver and passenger, optional side curtain airbags.

Seatbelts:

Three-point seat belts with pretensioners.

💡 Technology Features

Infotainment

Audio Options:

AM/FM stereo, CD player, cassette player (optional), premium sound systems available.

Navigation:

Optional factory navigation system.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Auxiliary Input:

Not commonly available on base models; aftermarket solutions often used.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

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

Oil Change Diesel:

Every 7,500-10,000 miles or 6-12 months with synthetic oil.

Transmission Fluid:

Check every 15,000 miles, change typically every 30,000-60,000 miles (varies by transmission type and usage).

Air Filter:

Inspect every 15,000 miles, replace as needed.

Spark Plugs Gasoline:

3.7L/4.7L V8: 100,000 miles (iridium), 5.7L HEMI: 100,000 miles (specific iridium plugs).

Fluid Specifications

Engine Oil 3.7L/4.7L:

SAE 5W-30, API certified, meeting Chrysler MS-6395.

Engine Oil 5.7L Hemi:

SAE 5W-20, API certified, meeting Chrysler MS-6395 (some early models may spec 5W-30).

Engine Oil 5.9L Cummins:

CJ-4 rated heavy-duty diesel engine oil, SAE 15W-40 recommended.

Transmission Fluid 42Rle/48Re:

ATF+4 (MS-9602).

Transfer Case Fluid:

ATF+4 (MS-9602) or Mopar transfer case fluid.

Coolant:

50/50 mix of Mopar Antifreeze/Coolant (MS-9769) or equivalent HOAT coolant.

Known Issues

Common Issues Gasoline Engines:

Head gasket leaks (4.7L V8), intake manifold gasket leaks, spark plug blowouts (early 5.7L HEMI).

Common Issues Diesel Engine:

Injectors, lift pump issues (less common on 2004 than earlier models), fuel supply issues.

Common Issues Transmission:

Torque converter shudder (48RE), planetary gear set failure (42RLE).

Common Issues Suspension:

Worn ball joints, tie rod ends, sway bar links due to vehicle weight and usage.

Common Issues Electrical:

TIPM (Totally Integrated Power Module) failures, blower motor resistor failures.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing durable and capable trucks, with the Ram line establishing itself as a significant player in the market.

Model Evolution

Third Generation:

The 2004 Ram is part of the third generation (2002-2008), characterized by a major redesign featuring a distinctive, bold exterior and a significantly upgraded interior.

Production

Manufacturing Location:

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