🏷️ Basic Information

Make:

Dodge

Model:

RAM 1500, 2500, 3500

Year:

2004

Chassis Code:

DR (Third Generation RAM)

👋 Introduction

Market Position:

The 2004 Dodge RAM series represented a significant evolution in the heavy-duty truck market, offering robust capability, a comfortable ride for its class, and distinctive styling. This generation (DR) was known for its blend of workhorse performance and consumer-friendly features.

Competitors:

Primary competitors included the Ford F-Series (F-150, F-250 Super Duty, F-350 Super Duty), Chevrolet Silverado 1500/2500HD/3500, and GMC Sierra 1500/2500HD/3500. The Dodge RAM distinguished itself with its unique front-end styling and often a more car-like interior compared to some competitors.

Segment Performance:

The 2004 RAM trucks were positioned as formidable contenders in the full-size pickup segment, particularly praised for their towing and hauling capabilities and the distinctive styling that set them apart from competitors.

Vehicle Features:

This generation of RAM trucks offered a range of powerful engine options, a refined interior for its time, substantial towing and payload capacities, and a reputation for durability, especially in its heavy-duty variants.

Manual Value Proposition:

This factory service manual is an indispensable tool for owners and technicians seeking to perform accurate diagnostics, maintenance, and repairs on their 2004 Dodge RAM. It provides the same detailed information utilized by dealership service departments.

📋 Manual Details

Coverage:

Complete service and repair coverage for all systems and components of the 2004 Dodge RAM 1500, 2500, and 3500 models.

Page Count:

Estimated 2000+ pages (typical for comprehensive factory service manuals of this era).

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, lubrication, cooling, fuel delivery, ignition, exhaust, intake, emissions control, engine diagnostics, complete transmission service (manual and automatic), transfer case, driveline, axles, differentials.

Chassis:

Frame and body structure, suspension systems (front and rear, including various leaf spring and coil spring configurations), steering system, brake systems (front and rear disc/drum, ABS, hydroboost), wheels and tires.

Electrical:

Battery, charging system, starting system, lighting, instrumentation, body control modules (BCM), power accessories (windows, locks, mirrors), HVAC controls, audio systems, trailer towing electrical interfaces, all diagnostic trouble codes (DTCs) and wiring diagrams.

Body And Interior:

Body panel removal and installation (hood, fenders, doors, tailgate), interior trim, seats, headliner, dashboard removal, HVAC system components (blower motor, evaporator, heater core, refrigerant system), power accessories, glass and seals.

Emissions And Diagnostics:

Detailed explanations of emissions control systems (catalytic converter, O2 sensors, EGR valve, PCV system), on-board diagnostics (OBD-II), diagnostic trouble codes (DTCs), and procedures for reading and clearing codes.

Wiring Diagrams:

Complete and detailed electrical wiring diagrams for all vehicle circuits, including power distribution, chassis control, engine control, body control, lighting, and accessory systems.

Repair Procedures:

Detailed step-by-step repair instructions for all major and minor components, including engine rebuilds, transmission overhauls, suspension and brake repairs, electrical system diagnosis and repair, body panel replacement, and interior trim removal/installation.

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation, and general chassis lubrication.

Diagnostic Procedures:

Comprehensive diagnostic routines for all vehicle systems, including symptom-based troubleshooting, diagnostic trouble code (DTC) interpretation, component testing, and electrical circuit analysis using wiring diagrams.

Troubleshooting Guides:

Systematic troubleshooting charts for common drivability issues, electrical faults, and mechanical problems, correlating symptoms to potential causes and diagnostic steps.

Specifications And Tolerances:

Comprehensive listing of all critical torque specifications for fasteners, engine bearing clearances, piston ring gaps, suspension component alignments, and wheel bearing adjustments.

Airbag System Repair:

Procedures for servicing the Supplemental Restraint System (SRS), including airbag module replacement, sensor calibration, and related electrical diagnostics. Emphasis on safety precautions when working with airbag systems.

Depth:

Factory-level technical depth covering component removal and installation, precise torque specifications, special tool requirements, rebuild procedures, and advanced diagnostic strategies.

Component Rebuilds:

Instructions for rebuilding major components such as cylinder heads, engine short blocks, automatic transmissions (45RFE, 48RE), and manual transmissions (NV5600, NV4500).

Diagnostic Tools:

Information on using diagnostic scan tools (e.g., DRB-III or compatible aftermarket tools) to retrieve DTCs, view live data streams, and perform actuator tests.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable PDF format, allowing users to quickly find specific topics, procedures, or components.

Print Quality:

High-resolution digital scans of original factory documentation, ensuring clear text and legible illustrations.

Illustration Clarity:

Illustrations and diagrams are reproduced with high clarity, accurately depicting component relationships, assembly sequences, and diagnostic points.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

4.7L Magnum V8 (235 hp @ 4500 rpm, 295 lb-ft @ 3200 rpm), 5.7L HEMI V8 (345 hp @ 5400 rpm, 375 lb-ft @ 4000 rpm), 5.9L Cummins Turbo Diesel I6 (250 hp @ 2900 rpm, 460 lb-ft @ 1600 rpm for manual trans; 275 hp @ 2900 rpm, 475 lb-ft @ 1600 rpm for automatic trans).

Engine Codes:

4.7L V8: EZH, 5.7L HEMI V8: ERA, 5.9L Cummins Turbo Diesel: DTR.

Horsepower Torque:

Varies by engine. The HEMI and Cummins diesel offered class-leading power and torque for their respective categories, crucial for towing and heavy hauling.

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI) for gasoline engines. Rotary injection pump for the Cummins diesel.

Ignition System:

Distributorless ignition system (DIS) with coil-on-plug (COP) technology for the V8 gasoline engines. Direct injection not applicable for this model year.

🔧 Transmission

Standard Transmission:

Varies by model and configuration. 5-speed manual transmission was common on lower trims and diesel models. 4-speed automatic transmission (45RFE/48RE) was widely available.

Automatic Transmission Codes:

45RFE (used with 4.7L V8), 48RE (used with 5.7L HEMI and 5.9L Cummins Diesel).

Manual Transmission Codes:

NV3500 (used with 4.7L V8 on some 1500 models), NV4500 (used with 5.9L Cummins Diesel on some models), NV5600 (optional 6-speed manual with 5.9L Cummins Diesel).

Optional Transmission:

6-speed manual transmission (NV5600) was optional on some heavy-duty models. Different automatic transmissions were available depending on engine and drivetrain configuration (e.g., 45RFE for 4.7L, 48RE for 5.7L and Cummins).

Transmission Features:

Tow/Haul mode on automatic transmissions, electronic shift-on-the-fly 4WD systems on many models, robust construction for heavy-duty applications.

📐 Dimensions

Overall Length:

Varies by cab and bed configuration, typically ranging from ~230 inches for regular cab short bed to over 260 inches for crew cab long bed.

Wheelbase:

Varies by configuration (e.g., 131.3" for 1500 regular cab short bed, 140.5" for 1500 quad cab short bed, 160.5" for 2500/3500 quad cab long bed).

Cab Configurations:

Regular Cab, Quad Cab (extended cab with rear doors).

Bed Lengths:

Short Bed (approx. 6.3 ft), Long Bed (approx. 8 ft).

Wheelbase Variants:

Specific wheelbases include approximately 131.3" (2WD/4WD Regular Cab Short Bed), 140.5" (2WD/4WD Quad Cab Short Bed), 160.5" (2WD/4WD Quad Cab Long Bed), 140.5" (2WD/4WD Regular Cab Long Bed), 148.9" (2WD/4WD Dually Long Bed).

Curb Weight:

Varies significantly by configuration, typically from around 4,800 lbs for a 1500 to over 6,500 lbs for a 3500 diesel crew cab long bed.

Payload Capacity:

Up to ~3,000 lbs for 1500 models, and significantly higher for 2500/3500 models (often exceeding 5,000 lbs).

Towing Capacity:

Up to ~10,000 lbs for properly equipped 1500 models, and over 13,000 lbs (or higher with proper configurations and hitch) for 2500/3500 models.

Gvw Ratings:

Gross Vehicle Weight Ratings vary by model and configuration, ranging from approximately 6,350 lbs for a 1500 to over 11,500 lbs for a 3500 dually.

🛡️ Safety Features

NHTSA Ratings:

Frontal crash ratings were generally good for the era. Side impact and rollover ratings should be reviewed individually. Refer to NHTSA archives for specific model year data.

Active Safety:

Anti-lock Braking System (ABS) standard on all models. Optional for some early models or specific trims was Hydroboost braking system. 4-wheel drive provided enhanced traction.

Parking Brake Type:

Rear drum parking brake, mechanically actuated.

Passive Safety:

Dual front airbags. Available side curtain airbags were not common on this generation. Seatbelt pre-tensioners. Heavy-duty frame construction contributed to occupant protection.

💡 Technology Features

Audio System:

Factory systems typically included AM/FM radio with CD player, and optional premium Infinity sound systems with subwoofer. Cassette players were still available on some base models.

Navigation:

Factory navigation systems were not commonly offered on this generation of RAM trucks, with aftermarket solutions being more prevalent.

Display Screen:

Optional infotainment systems may have included a small monochrome display for radio information and climate control, but no large touchscreen displays were factory standard.

Driver Assistance Features:

Limited advanced driver-assistance systems (ADAS) by modern standards. Features included cruise control, power adjustable pedals (on some higher trims), and available rear parking assist sensors.

Connectivity Options:

Basic connectivity features included 12V power outlets. Auxiliary audio input jacks were not standard on early models of this generation but became more common. No integrated Bluetooth or USB ports from the factory.

🔧 Maintenance

Oil Change Interval:

Typically 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (severe vs. normal). Refer to manual for exact recommendations based on engine and oil specification.

Transmission Fluid Interval:

Automatic transmission fluid (ATF) flush and replacement typically recommended every 30,000-60,000 miles, especially for heavy towing. Manual transmission fluid and transfer case fluid intervals are generally longer (e.g., 60,000-100,000 miles).

Coolant Interval:

Extended life coolant often recommended for initial fill, with replacement intervals typically at 100,000 miles or 5 years for the first service, then every 50,000-75,000 miles or 3-5 years thereafter.

Spark Plug Replacement Interval:

For 4.7L V8 and 5.7L HEMI V8: Typically around 100,000 miles with the original platinum-tipped spark plugs. For Cummins diesel: Fuel filter replacement is critical, usually at 15,000-30,000 miles.

Engine Oil Spec:

For 4.7L V8: SAE 5W-30. For 5.7L HEMI V8: SAE 5W-20 (refer to manual for specific viscosity based on climate). For 5.9L Cummins: SAE 15W-40 (diesel specific oil, e.g., API CJ-4 or equivalent).

Transmission Fluid Spec:

For 45RFE/48RE automatics: ATF+4 (Chrysler part number 05013457AA or equivalent). For NV5600 manual: SAE 75W-90 synthetic gear oil. For NV4500: SAE 75W-90 synthetic gear oil.

Coolant Spec:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar antifreeze/coolant, 5-year/100,000 mile formula (typically orange or red in color).

Brake Fluid Spec:

DOT 3 brake fluid.

Power Steering Fluid Spec:

Chrysler ATF+4 or specific Mopar power steering fluid.

Common Wear Items:

Ball joints and tie rod ends on front suspension, U-joints on driveshafts, brake component wear (pads, rotors, drums), radiator and cooling system leaks, water pump failures, and exhaust manifold cracks (especially on HEMI).

Diesel Specific Issues:

Injection pump issues, injector failures, and potential for turbocharger wear over time. Fuel filter replacement is critical for longevity. EGR system issues can occur.

Electrical Quirks:

Occasional issues with power window motors, door lock actuators, and instrument cluster failures. Body Control Module (BCM) issues can affect various accessories.

Automatic Transmission Issues:

Overheating issues on the 48RE transmission during heavy use, requiring auxiliary coolers. Valve body issues can also arise.

📚 Vehicle History

Dodge Truck Heritage:

Dodge has a long and storied history in the truck market, with the RAM nameplate becoming synonymous with toughness and capability since its introduction in 1981. Dodge trucks have consistently challenged the market with innovative designs and powerful powertrains.

Third Generation Ram:

The 2004 models belong to the third generation of RAM trucks (introduced for the 2002 model year), which featured a complete redesign with a larger, more aggressive exterior, a significantly improved interior, and updated powertrains including the introduction of the 5.7L HEMI and the continuation of the robust Cummins turbodiesel.

Third Generation Enhancements:

Key enhancements for the third generation included a significantly stiffer frame, independent front suspension (on 1500 models) for improved ride and handling, and the introduction of the HEMI engine, which became a hallmark of Dodge performance.

Key Model Changes 2004:

While the third generation was largely established, minor updates or packaging changes might have occurred for the 2004 model year. The 5.7L HEMI V8 gained wider availability across trims.

Manufacturing Locations:

Primarily produced at the Warren Truck Assembly Plant in Warren, Michigan, and the Saltillo Truck Assembly Plant in Saltillo, Coahuila, Mexico.