🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck

Model Variant:

1500, 2500, 3500

Production Year:

2004

Chassis Code:

DR (2nd Generation - Last Year)

👋 Introduction

Segment:

Full-size pickup truck.

Brand Strength:

Dodge Ram trucks were known for their robust build, towing capacity, and powerful engine options, particularly the HEMI and Cummins.

Key Competitors:

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

Notable Features:

Introduced the HEMI V8 in 2003, RamBox cargo management system (though not standard on all 2004 models), improved interior comfort and design over previous generations.

Utility:

Essential for owners and independent repair shops to perform accurate diagnostics, maintenance, and repairs, saving significant costs over dealership services.

📋 Manual Details

General Coverage:

All models (1500, 2500, 3500) and all engine variants for the 2004 model year.

Estimated Page Count:

Extensive; likely several thousand pages covering all systems.

Type:

Complete Official Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Detailed coverage for 5.7L HEMI V8, 4.7L Magnum V8, and 5.9L Cummins Turbo Diesel engines. Includes diagnostics, repair, overhaul, specifications, and torque values.

Transmission:

Coverage for manual transmissions (NV3500, G56) and automatic transmissions (45RFE, 48RE). Includes operation, diagnostics, disassembly, assembly, and fluid specifications.

Drivetrain:

Front and rear axle assemblies, differentials, drive shafts, U-joints, transfer cases (manual and electronic shift), and wheel bearings.

Suspension:

Front independent suspension (IFS) for 1500, solid front axle for 2500/3500. Rear leaf spring suspension. Includes components, alignment, shock absorbers, springs, bushings, and steering linkage.

Brakes:

Front disc brakes, rear drum or disc brakes (depending on configuration). ABS system, hydraulic lines, master cylinder, calipers, pads, rotors, and parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter), ignition system, lighting (headlights, taillights, interior), power accessories (windows, locks), fuses, relays, and wiring diagrams.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, and EVAP system.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant hoses, and heater core.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, tailpipe, and emissions control components.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant R134a, compressor, condenser, evaporator, and controls.

Body:

Body panels, doors, hood, tailgate, bumpers, interior trim, glass, and seals.

Chassis:

Frame construction, crossmembers, and mounting points.

Diagnostic Troubleshooting:

Extensive guides for diagnosing and troubleshooting common and complex issues, including symptom-based diagnostics.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, and brake inspections.

Repair:

Detailed step-by-step repair procedures for all major components and systems, including engine rebuilds, transmission overhauls, suspension and brake repairs.

Overhaul:

Complete overhaul procedures for engines, transmissions, and axle assemblies.

Replacement:

Procedures for replacing all wear items and common failure parts like water pumps, alternators, starters, fuel pumps, and HVAC components.

Diagnostics:

Diagnostic flowcharts, trouble codes (OBD-II), sensor testing, and component testing procedures.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and factory procedures.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text within the PDF for quick information retrieval.

Quality:

High-resolution scans of original factory documentation, ensuring clear diagrams and text.

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine 1:

5.7L HEMI V8 (345 CID)

Engine 1 Power:

345 hp @ 5000 rpm

Engine 1 Torque:

375 lb-ft @ 3200 rpm

Engine 2:

4.7L Magnum V8 (285 CID)

Engine 2 Power:

235 hp @ 4500 rpm

Engine 2 Torque:

295 lb-ft @ 3200 rpm

Engine 3:

5.9L Cummins Turbo Diesel (359 CID)

Engine 3 Power:

250 hp @ 2900 rpm (approx.)

Engine 3 Torque:

460 lb-ft @ 1400 rpm (approx.)

Induction:

Electronic Fuel Injection (MPI for gasoline, Common Rail for diesel)

Fuel Type:

Unleaded Gasoline (87 octane recommended), Diesel Fuel

🔧 Transmission

Transmission 1500:

45RFE 4-speed Automatic (standard on most 1500 models)

Transmission 2500 3500:

48RE 4-speed Automatic (heavy-duty)

Transmission 1500 Manual:

NV3500 5-speed Manual

Transmission 2500 3500 Manual:

G56 6-speed Manual (late 2004 models for diesel)

Transfer Case:

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

Automatic Fluid Type:

ATF+4 (Chrysler Material Standard MS-9602)

Manual Fluid Type:

Manual Transmission Fluid (MTF) - consult manual for specific viscosity

📐 Dimensions

Wheelbase 1500:

134.2 inches (standard cab), 148.7 inches (club cab/quad cab)

Wheelbase 2500 3500:

134.2 inches (standard cab), 148.7 inches (club cab/quad cab), 160.3 inches (crew cab long bed)

Bed Lengths:

6.3 ft (short bed), 8.0 ft (long bed)

Curb Weight Approx:

4800 - 7000 lbs (depending on configuration)

Gvwr Approx:

6350 - 11500 lbs (depending on configuration)

Towing Capacity Max:

Up to 13,000 lbs (for properly equipped 3500 models)

Payload Capacity Max:

Up to 5,000 lbs (for properly equipped 3500 models)

🛡️ Safety Features

NHTSA Rollover Rating:

Generally 3 out of 5 stars (similar to competitors in its class)

ABS:

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

Airbags:

Driver and passenger front airbags standard.

Seatbelts:

Three-point seat belts with pretensioners.

Construction:

Body-on-frame construction with reinforced safety cage.

💡 Technology Features

Audio Options:

AM/FM stereo with CD player, optional cassette player, Sirius Satellite Radio capability. Basic speaker systems, optional premium Infinity sound system.

Features:

Limited by modern standards; primarily focused on mechanical systems. Features like cruise control, power windows/locks, and adjustable steering column were common.

Features:

No advanced connectivity features like Bluetooth or USB ports standard. Optional auxiliary audio input.

🔧 Maintenance

Oil Change Gasoline:

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

Oil Change Diesel:

Every 7,500 miles or 6 months (synthetic oil recommended for optimal performance).

Filter Replacement:

Air filter: 15,000-30,000 miles. Fuel filter: 15,000-30,000 miles (gasoline), 30,000 miles (diesel, recommended).

Engine Oil Gasoline:

SAE 5W-30 (most engines), SAE 10W-30 (some older specs). API Certified.

Engine Oil Diesel:

SAE 15W-40 (CK-4 or CJ-4 rated) recommended for Cummins 5.9L.

Coolant:

Chrysler Formula 50/50 Antifreeze/Coolant (MS-7170 for gasoline, MS-10106 for diesel) or equivalent.

Brake Fluid:

DOT 3.

Common Problems:

Fuel pump failures, ball joint wear (especially on IFS 1500), transmission solenoid issues (45RFE/48RE), exhaust manifold leaks (HEMI), vacuum pump leaks (diesel), heater core leaks, death wobble (rare, but possible with worn steering/suspension components).

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks, with the Ram line being a cornerstone since its introduction in 1981.

Second Generation Ram:

The 2004 model year marks the final year of the second-generation Dodge Ram (DR platform), which ran from 1994 to 2001 and was updated for 2002. This generation introduced the distinctive 'big rig' styling.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan.

🏆 Awards & Recognition

Engine Awards:

The 5.7L HEMI V8 was widely praised for its power and sound, contributing to Ram's performance image.

Model Segment Awards:

Ram trucks consistently received positive reviews in automotive press for towing and hauling capabilities, and interior comfort within its class.