2004 Dodge Ram 3500

The 2004 Dodge Ram 3500 is a heavy-duty pickup truck known for its towing capacity and robust design. Available engines included the 5.7L Hemi V8, the 5.9L Cummins Turbo Diesel, and the 8.0L Magnum V10. The 5.9L Cummins is a popular choice, producing 325 horsepower and 600 lb-ft of torque, coveted for its reliability and longevity. Transmission options included a 5-speed manual, a 6-speed manual, and a 4-speed automatic. Owners often praise the Ram 3500 for its powerful engine options and towing capabilities, while common complaints include issues with front end suspension components and electrical glitches.

Engine

5.9L Cummins Turbo Diesel

• Lift Pump Failure
  • Description/Symptoms: The lift pump, responsible for supplying fuel to the high-pressure injection pump (VP44), is prone to failure. Symptoms include hard starting, loss of power, and eventual failure of the VP44 injection pump due to fuel starvation.
  • Solution: Replace the lift pump with an upgraded aftermarket pump that provides better fuel flow and reliability. Relocate the lift pump closer to the fuel tank.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• VP44 Injection Pump Failure
  • Description/Symptoms: The VP44 is an electronically controlled rotary injection pump. It is sensitive to fuel pressure and quality. When the lift pump fails, or fuel isn’t properly filtered, the VP44 can fail. Symptoms include hard starting, rough idling, loss of power, and stalling.
  • Solution: Replace the VP44 injection pump. Install a fuel pressure gauge to monitor fuel pressure and prevent future failures. Ensure fuel is properly filtered.
  • Estimated Cost to Fix: $1,000 - $2,500+
  • Recalls: None Found

5.7L Hemi V8

• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: The exhaust manifold bolts are known to break, causing an exhaust leak. This can result in a ticking noise, reduced fuel economy, and potential damage to other components.
  • Solution: Replace the broken exhaust manifold bolts with updated, stronger bolts. In some cases, the exhaust manifold may need to be replaced as well.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Transmission

48RE 4-Speed Automatic

• Overdrive Clutch Failure
  • Description/Symptoms: The 48RE transmission is known to experience overdrive clutch failure, especially under heavy towing or aggressive driving conditions. Symptoms include slipping in overdrive, delayed engagement, and eventual failure of the transmission.
  • Solution: Rebuild or replace the transmission with an upgraded unit that includes stronger overdrive clutches and improved lubrication.
  • Estimated Cost to Fix: $2,500 - $5,000+
  • Recalls: None Found

NV5600 6-Speed Manual

• 5th Gear Nut Loosening
  • Description/Symptoms: The NV5600 transmission, particularly those subjected to heavy loads and high mileage, can experience the 5th gear nut loosening on the main shaft. This leads to gear slippage, noise, and eventual failure of the 5th gear.
  • Solution: Repair or replace the transmission with a rebuilt unit that has an updated 5th gear nut and shaft. Some shops will machine the shaft to prevent the nut from backing off.
  • Estimated Cost to Fix: $2,000 - $4,000+
  • Recalls: None Found

Suspension

• Front End Ball Joint Wear
  • Description/Symptoms: The front end ball joints are prone to wear, especially on trucks that are frequently used for towing or hauling heavy loads. Symptoms include clunking noises, loose steering, and uneven tire wear.
  • Solution: Replace the worn ball joints with upgraded, heavy-duty ball joints. It is often recommended to replace all ball joints at the same time.
  • Estimated Cost to Fix: $400 - $1,000+
  • Recalls: None Found
• Track Bar Issues
  • Description/Symptoms: The track bar helps keep the axle centered under the vehicle. The track bar bushings wear out and can cause “Death Wobble”.
  • Solution: Replace the Track Bar and bushing, or purchase and install an aftermarket Track Bar.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: The instrument cluster is prone to failure. Symptoms include gauges not working properly, flickering lights, or complete failure of the cluster.
  • Solution: Replace or repair the instrument cluster. Some repair shops specialize in rebuilding instrument clusters.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• Wiring Harness Chafing
  • Description/Symptoms: The wiring harness can chafe against the frame or other components, causing shorts and electrical issues. Symptoms include intermittent electrical problems, blown fuses, and warning lights.
  • Solution: Inspect the wiring harness for chafing and repair any damaged wires. Secure the harness to prevent future chafing.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found

Exterior

• Cab Corner Rust
  • Description/Symptoms: The cab corners are prone to rusting, especially in areas with harsh winters and road salt.
  • Solution: Repair or replace the rusted cab corners. This can involve welding in new metal and repainting.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: The dashboard is known to crack, especially in hot climates or with extended sun exposure.
  • Solution: Replace the dashboard or install a dashboard cover.
  • Estimated Cost to Fix: $300 - $1,000+
  • Recalls: None Found

Summary:

The 2004 Dodge Ram 3500, particularly with the Cummins diesel engine, remains a popular truck. The severity and cost of common issues vary, but the potential for lift pump/VP44 failure on the Cummins diesel and overdrive clutch problems on the 48RE transmission can lead to expensive repairs. Front-end suspension component wear and electrical gremlins are also common. Addressing these issues proactively can help extend the life and reliability of this heavy-duty truck.