DODGE 2500 RAM Truck 2004 (DR) Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2004 Internal Code: DR 👋 Introduction Market Position Segment: Full-size Heavy Duty Pickup Truck Target Audience: Owners, professional technicians, DIY...

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类型: Truck

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标签: 2004 2500 RAM Cars Dodge Misc Truck

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Year:

Internal Code:

👋 Introduction

Market Position

Segment:

Full-size Heavy Duty Pickup Truck

Target Audience:

Owners, professional technicians, DIY enthusiasts performing maintenance and repairs

Competitive Analysis

Key Competitors:

Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD

Key Features

Vehicle Strengths:

Robust construction, towing and hauling capability, durable powertrains

Manual Purpose:

To provide definitive guidance for maintaining and repairing the 2004 Dodge Ram 2500 (DR) platform

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Likely digital (PDF) or printed book

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder heads, crankshaft, camshaft, pistons, connecting rods, lubrication system, cooling system

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system (ECM diagnostics), emission controls

Transmission Manual:

Clutch, gearbox assembly, shift mechanisms, PTO (if applicable)

Transmission Automatic:

Torque converter, valve body, gear sets, cooling system, electronic controls (TCM diagnostics)

Driveline:

Driveshafts, universal joints, axle assemblies (front and rear), differentials

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), parking brake, brake components (rotors, calipers, pads, lines)

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, ball joints, steering knuckles

Steering:

Steering column, steering gear, power steering system, tie rods

Exhaust:

Exhaust manifolds, catalytic converter, mufflers, exhaust pipes

Fuel:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injection system

Cooling:

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

Electrical Body:

Lighting, wipers, power windows, power locks, mirrors, horns, interior controls

HVAC:

Heating, Ventilation, and Air Conditioning system components, operation, and service

Chassis Frame:

Frame construction, body mounting, corrosion protection

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, glass, trim

Body Interior:

Seats, dashboard, door panels, headliner, carpeting

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), diagnostic procedures for various systems

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, inspections

Component Replacement:

Detailed step-by-step instructions for replacing common wear items and components

Troubleshooting Guides:

Systematic approaches to diagnose and resolve common and uncommon vehicle issues

Electrical Diagnostics:

Wiring diagrams, component testing procedures, circuit analysis

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly procedures for engine components

Transmission Rebuild:

Detailed instructions for the repair and rebuilding of both manual and automatic transmissions

Brake System Service:

Bleeding procedures, component replacement (pads, rotors, calipers), ABS system diagnostics

Suspension And Steering Repair:

Alignment specifications, component replacement, power steering system service

HVAC Service:

Refrigerant handling, component testing, system diagnostics and repair

Body Work:

Panel alignment, repair techniques, glass replacement (may be limited)

Technical Depth

Depth:

Comprehensive, covering from routine maintenance to major component overhauls and advanced diagnostics

📊 Manual Specifications

File Format

File Type:

Likely PDF, but could be printed

Searchability:

If PDF, generally searchable by keywords

Print Quality

Print Format:

If printed, typically high-quality paper with clear diagrams and text

Binding Type

Binding If Printed:

Likely spiral-bound or perfect-bound for durability and ease of use

Paper Type

Paper Quality If Printed:

Durable, often glossy or semi-glossy paper for illustrations and diagrams

⚙️ Engine Specifications

Primary Engine

Engine Options:

5.7L HEMI V8, 5.9L Cummins I6 Turbo Diesel (likely covered extensively given the heavy-duty nature)

Performance 5.7L Hemi

Displacement Hemi:

5.7 Liters

Horsepower Hemi:

Approx. 345 hp

Torque Hemi:

Approx. 375 lb-ft

Performance 5.9L Cummins

Displacement Cummins:

5.9 Liters

Horsepower Cummins:

Approx. 305 hp (specific output varied slightly by model year and trim)

Torque Cummins:

Approx. 555 lb-ft (specific output varied slightly by model year and trim)

Fuel System

Fuel Type Hemi:

Unleaded Gasoline

Fuel System Type Hemi:

Multi-port Fuel Injection (MPI)

Fuel Type Cummins:

Diesel

Fuel System Type Cummins:

High-pressure Common Rail (HPCR) Injection System

🔧 Transmission

Standard Transmission

Standard Option:

Manual Transmission (e.g., NV4500 5-speed for diesel, Getrag for gas)

Optional Transmission

Optional Option:

Automatic Transmission (e.g., 48RE 4-speed for diesel, 45RFE/545RFE 4-speed for gas)

Features

Transmission Cooling:

Includes procedures for automatic transmission fluid cooler service and inspection

Transfer Case:

Covers 4WD transfer case operation, maintenance, and repair

📐 Dimensions

Exterior Typical

Wheelbase:

Varies by cab and bed configuration (e.g., 135.0" for Regular Cab Long Bed, 140.5" for Quad Cab Short Bed)

Overall Length:

Varies by configuration (e.g., approx. 229.7" to 260.7")

Weights

Gvwr:

Typically around 8,800 lbs to 9,500 lbs (depending on configuration)

Curb Weight:

Varies significantly by engine, drivetrain, and cab/bed configuration

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Good (for models tested, specific year data may vary)

Active Features

Standard Anti-lock Braking System

Traction Control:

Available (e.g., Electronic Brake Force Distribution)

Passive Features

Airbags:

Driver and Passenger Front Airbags

Seatbelts:

Three-point front and rear seatbelts

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional cassette player, available Infinity audio system

Navigation:

Not typically available on this model year, optional dealer-installed systems may exist

Driver Assistance

Cruise Control:

Standard

Rear Parking Assist:

Optional

Connectivity

Power Outlets:

12V auxiliary power outlets

Trailer Tow Connector:

Standard 4-pin and optional 7-pin trailer connectors

🔧 Maintenance

Service Intervals Gasoline

Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics)

Air Filter Replacement:

Every 12,000-15,000 miles or as needed based on inspection

Spark Plug Replacement:

Approx. 30,000-100,000 miles (depending on spark plug type, e.g., copper vs. platinum)

Service Intervals Diesel

Oil Change Interval Cummins:

Every 5,000-7,500 miles or 6 months (often recommended with high-quality diesel oil)

Fuel Filter Replacement Cummins:

Every 15,000-30,000 miles or annually

Coolant Flush Interval:

Every 30,000-50,000 miles or 2-3 years (depending on coolant type)

Fluid Specifications

Engine Oil Hemi:

SAE 5W-20, API Certified (refer to manual for specific viscosity and API rating requirements)

Engine Oil Cummins:

SAE 15W-40, API CJ-4 or CK-4 rated diesel engine oil (refer to manual for specific viscosity and API rating requirements)

Coolant:

Mopar OAT (Organic Additive Technology) or equivalent HOAT coolant, typically 50/50 mix with distilled water

Transmission Fluid Automatic:

ATF+4 (Automatic Transmission Fluid Type 96)

Transmission Fluid Manual:

Refer to manual for specific gear oil viscosity (e.g., GL-3 or GL-4 for NV4500)

Brake Fluid:

DOT 3 or DOT 4, per manufacturer's specification

Known Issues

Common Hem Issues:

Lifter tick, camshaft wear (in earlier versions), some ignition coil failures

Common Cummins Issues:

Injector pump issues (in some earlier versions), transmission cooler line leaks, EGR system maintenance

Front End Wear:

Ball joint and tie rod end wear due to vehicle weight and suspension design

Frame Corrosion:

Potential for frame rust, especially in areas with road salt (manual will cover inspection)

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long-standing history of producing robust and capable trucks.

Model Evolution

Third Generation Ram:

The 2004 model is part of the third generation of Ram trucks (2002-2008), which featured a significant redesign with improved aerodynamics and a more integrated appearance.

Powertrain Updates:

The introduction of the 5.7L HEMI V8 in 2003 was a major upgrade for gasoline models, and the 5.9L Cummins Turbo Diesel continued its reputation for durability.

Production

Manufacturing Location:

Saltillo, Mexico, and Warren, Michigan, USA (for various configurations)