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2004 Dodge Ram 2500

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By Research the Car 5 min read

The 2004 Dodge Ram 2500 is a heavy-duty pickup truck known for its ruggedness and capability. It came with several engine options, including the 5.7L HEMI V8 (345 hp, 375 lb-ft of torque), the 5.9L Cummins Turbo Diesel inline-6 (325 hp, 600 lb-ft of torque), and the 8.0L Magnum V10 (310 hp, 450 lb-ft of torque). Transmission options included a 5-speed manual, a 6-speed manual, and a 4-speed automatic. People generally like the Ram 2500 for its powerful engine options, towing capacity, and comfortable ride for a heavy-duty truck. Common complaints include fuel economy, some electrical issues, and potential rust.

Engine

5.7L HEMI V8

  • Valve Seat Failure
    • Description/Symptoms: Ticking noise, misfires, loss of compression, potentially leading to engine damage. Often occurs at higher mileage.
    • Solution: Engine rebuild or replacement of cylinder heads with upgraded valve seats.
    • Estimated Cost to Fix: $3,000 - $6,000+
    • Recalls: None Found
  • Manifold Bolts Breaking
    • Description/Symptoms: Exhaust leak sound, decreased fuel economy.
    • Solution: Replace broken manifold bolts and possibly the exhaust manifold itself.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found

5.9L Cummins Turbo Diesel

  • Lift Pump Failure
    • Description/Symptoms: Hard starting, loss of power, stalling. The lift pump supplies fuel to the injection pump, and failure can starve the engine of fuel.
    • Solution: Replace the lift pump. Upgrading to an aftermarket pump (such as a Fass or AirDog) is a common preventative measure.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found
  • Injection Pump (VP44) Failure
    • Description/Symptoms: Hard starting, loss of power, stalling, check engine light. This is a common failure point on the 5.9L Cummins with the VP44 injection pump.
    • Solution: Replace the VP44 injection pump.
    • Estimated Cost to Fix: $1,500 - $3,000+
    • Recalls: None Found
  • Injector Issues
    • Description/Symptoms: Misfires, rough running, white smoke, fuel dilution in the oil.
    • Solution: Replace faulty injectors.
    • Estimated Cost to Fix: $400 - $2,000+ (depending on the number of injectors replaced)
    • Recalls: None Found

8.0L Magnum V10

  • No Issues Found

Transmission

4-Speed Automatic (48RE)

  • Overdrive Clutch Failure
    • Description/Symptoms: Slipping in overdrive, failure to shift into overdrive, transmission overheating.
    • Solution: Transmission rebuild or replacement, including replacement of the overdrive clutches.
    • Estimated Cost to Fix: $2,000 - $4,000+
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering, slipping, transmission overheating, abnormal noises.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $500 - $1,500+
    • Recalls: None Found

5-Speed Manual (NV4500)

  • 5th Gear Failure
    • Description/Symptoms: 5th gear pops out, grinds, or is lost entirely.
    • Solution: Transmission rebuild or replacement, often with an upgraded 5th gear nut.
    • Estimated Cost to Fix: $2,000 - $4,000+
    • Recalls: None Found

6-Speed Manual (NV5600)

  • Input Shaft Bearing Failure
    • Description/Symptoms: Loud whining noise that increases with engine speed, especially noticeable in lower gears. Can eventually lead to complete transmission failure.
    • Solution: Transmission rebuild, including replacement of the input shaft bearing and potentially other damaged components.
    • Estimated Cost to Fix: $2,500 - $4,500+
    • Recalls: None Found

Suspension

  • Ball Joint Failure
    • Description/Symptoms: Popping or clunking noise from the front end, especially when turning or going over bumps, uneven tire wear, loose steering.
    • Solution: Replace worn or damaged ball joints.
    • Estimated Cost to Fix: $300 - $800+ per side
    • Recalls: None Found
  • Track Bar Issues
    • Description/Symptoms: Death wobble, loose steering, wandering on the road.
    • Solution: Replace worn track bar bushings or the entire track bar, potentially upgrading to a heavier-duty aftermarket track bar.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found

Electrical

  • PCM Failure
    • Description/Symptoms: Various engine and transmission problems, stalling, no start condition, check engine light.
    • Solution: Replace the Powertrain Control Module (PCM). May require programming.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found
  • Instrument Cluster Issues
    • Description/Symptoms: Gauges not working properly, flickering lights, complete failure of the instrument cluster.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found
  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, shorts, open circuits, affecting various systems.
    • Solution: Diagnose and repair damaged wiring harness sections.
    • Estimated Cost to Fix: $200 - $1000+ (depending on the extent of the damage)
    • Recalls: None Found

Exterior

  • Rust (Cab Corners, Rocker Panels)
    • Description/Symptoms: Rust forming on cab corners and rocker panels.
    • Solution: Cut out rusted metal and weld in new panels, followed by bodywork and paint.
    • Estimated Cost to Fix: $500 - $2000+ (depending on the severity and extent of the rust)
    • Recalls: None Found

Interior

  • Dashboard Cracking
    • Description/Symptoms: Large cracks appearing on the dashboard, especially in hot climates.
    • Solution: Dashboard replacement or installation of a dashboard cover.
    • Estimated Cost to Fix: $200 - $1000+
    • Recalls: None Found

Summary

The 2004 Dodge Ram 2500 has some common issues to be aware of, depending on the engine and transmission combination. The 5.7L HEMI can suffer from valve seat and exhaust manifold bolt issues. The 5.9L Cummins is prone to lift pump and injection pump failures, as well as injector problems. Transmission issues vary depending on whether it’s the automatic or manual. The NV4500 5-speed manual can experience 5th gear failure, while the NV5600 6-speed manual can have input shaft bearing issues. The automatic transmissions are prone to overdrive clutch and torque converter failure. Suspension problems like ball joint and track bar wear are also common. Electrical issues like PCM failure, instrument cluster problems, and wiring harness issues can also arise. Finally, rust on the cab corners and rocker panels is a known issue. The severity and cost of these issues can range from relatively minor repairs to major overhauls, so it’s important to thoroughly inspect any potential purchase and address any existing problems promptly.

Dodge, Ram 2500
Dodge Ram 2500 2004
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