Segment:
Heavy-duty pickup truck segment.
Key Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Vehicle Strengths:
Renowned for robust powertrain options, towing and hauling capability, and overall durability. Third-generation Ram offered significant design and capability improvements.
Target Audience:
Professional mechanics, automotive repair shops, experienced DIY enthusiasts, fleet managers.
Coverage Scope:
Comprehensive service and repair for all Dodge Ram 1500, 2500, and 3500 models for the 2004 model year.
Estimated Page Count:
Over 2000 pages (typical for comprehensive factory service manuals of this era).
Type:
Factory Service Manual / Workshop Manual
Format:
Digital (likely PDF, as implied by common sales practices for these manuals).
Engine Systems:
Engine mechanical, lubrication, cooling, fuel and exhaust, ignition, starting, charging, engine control systems (ECM/PCM).
Transmission Drivetrain:
Manual and automatic transmissions (e.g., NV4500, 48RE, 47RE, NV5600), transfer cases, drive shafts, axles, differentials, power takeoff (PTO).
Brakes Suspension Steering:
Brake system (ABS, hydraulics, calipers, rotors, pads), suspension components (front and rear, springs, shocks, control arms), steering system (rack and pinion, power steering, tie rods).
Electrical Electronic:
Battery, charging system, starting system, lighting, instrument cluster, body control modules (BCM), power distribution, wiring diagrams, fuses, relays, diagnostic connectors.
Body Chassis:
Body panels, interior trim, seats, doors, windows, tailgate, frame, bumpers, exhaust system routing, HVAC system.
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication, belt and hose inspection/replacement.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs), power flow charts, signal tracing.
Repair Procedures:
Step-by-step instructions for component removal, installation, overhaul, and adjustment.
Specification Data:
Torque specifications, clearances, fluid capacities, diagnostic parameters, alignment specifications.
Depth:
Professional-level, suitable for factory-trained technicians. Covers complete engine rebuilds, transmission overhauls, complex electrical diagnostics, and body repair.
Engine Options:
5.7L HEMI V8 (e.g., Magnum), 5.9L Cummins Turbo Diesel I6, 4.7L Magnum V8, 3.7L Magnum V6 (primarily 1500).
5.7L Hemi V8 Horsepower:
Approximately 345-360 hp (varies by specific tuning).
5.7L Hemi V8 Torque:
Approximately 375-395 lb-ft (varies by specific tuning).
5.9L Cummins Turbo Diesel Horsepower:
Approximately 250-325 hp (varies by trim and turbocharger).
5.9L Cummins Turbo Diesel Torque:
Approximately 460-555 lb-ft (varies by trim and turbocharger).
Fuel Delivery:
Multi-point fuel injection (MPI) for gasoline engines, common rail direct injection for Cummins diesel.
ECM PCM Type:
Specific powertrain control modules (PCMs) depending on engine and transmission.
Standard Transmission:
Varies by model and engine. Common options include 5-speed manual and 4-speed automatic.
Optional Transmission:
5-speed manual (NV4500, NV5600 for diesel and heavy duty), 4-speed automatic (47RE, 48RE for diesel and heavy duty).
Transfer Case:
Part-time 4WD system with electronic or manual shift options.
Automatic Transmission Fluid:
ATF+4 (Chrysler spec) for automatic transmissions.
Manual Transmission Fluid:
Refer to specific manual for NV4500/NV5600; typically GL-4 or GL-5 rated gear oil.
Wheelbase Options:
Various wheelbases available (e.g., 130.5", 140.5", 159.5", 167.5" depending on cab and bed configuration).
Overall Length:
Varies significantly by configuration (e.g., Regular Cab Long Bed vs. Crew Cab Short Bed).
Gvwr Range:
Gross Vehicle Weight Rating (GVWR) varies from approximately 8,510 lbs (1500) to over 12,000 lbs (3500).
Curb Weight:
Approximately 5,000 lbs to 7,000+ lbs depending on configuration.
NHTSA Front Impact:
Refer to specific NHTSA reports for 2004 model year; generally good for the era.
IIHS Crash Test:
Refer to specific IIHS reports for 2004 model year.
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Available Traction Control System (TCS).
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point seat belts with pretensioners.
Audio System:
AM/FM stereo with CD player, cassette tape player (optional), and speaker configurations depending on trim level.
Navigation:
Factory navigation systems were optional on higher trim levels.
Cruise Control:
Standard or optional cruise control.
Power Accessories:
Power windows, power locks, power mirrors available on higher trims.
Oil Change Interval:
Typically 3,000-7,500 miles or 6 months, depending on engine type, oil quality, and driving conditions. Refer to manual for exact specifications.
Transmission Fluid Change:
Automatic transmissions: 30,000-60,000 miles or as needed. Manual transmissions: 60,000-100,000 miles. Always consult manual.
Coolant Change:
Typically every 30,000-60,000 miles or as specified for the coolant type.
Engine Oil Type Gas:
e.g., SAE 5W-30 or 10W-30, API SN or higher (refer to owner's manual for exact specification).
Engine Oil Type Diesel:
e.g., SAE 15W-40, API CJ-4 or equivalent for Cummins (refer to owner's manual).
Coolant Type:
Mopar OAT (Organic Additive Technology) or equivalent HOAT coolant.
Common Diesel Issues:
Lift pump failures, injector issues, VP44 injection pump problems (early models), exhaust manifold leaks, turbocharger wastegate issues.
Common Gas Issues:
Crankshaft position sensor failures, EGR valve issues, intake manifold leaks, piston slap (some 4.7L engines), catalytic converter failures.
Transmission Issues:
Torque converter shudder, solenoid issues in automatic transmissions, clutch wear in manual transmissions.
Suspension Steering Issues:
Ball joint wear, tie rod wear, steering box looseness, shock absorber failure.
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks, with the Ram line dating back to 1981, evolving significantly over generations.
Third Generation Ram:
The 2004 model year represents the third generation of the Ram truck (introduced for 2002), known for its distinct styling, improved interior, and enhanced powertrains.
Manufacturing Location:
Primarily St. Louis Assembly Plant (Missouri, USA) and Saltillo Truck Assembly Plant (Mexico).
