2004 Dodge Sprinter 2500

Introduction: The 2004 Dodge Sprinter 2500 is a versatile commercial van known for its spacious cargo area and powerful engine options. It came with a standard 2.7L inline-5 turbocharged diesel engine producing 154 hp and 240 lb-ft torque, paired with a 5-speed manual transmission. A 3.0L V6 turbocharged diesel engine with 177 hp and 332 lb-ft torque was optional, paired with either a 5-speed automatic or a 6-speed manual transmission. Owners appreciate the Sprinter 2500’s durability and cargo capacity but find its fuel economy lacking.

Engine

2.7L Inline-5 Turbocharged Diesel Engine

• Oil Pan Gasket Leak: – Description/Symptoms: Leaking oil from the oil pan area, visible on the ground or engine underside. – Solution: Replace oil pan gasket. – Estimated Cost to Fix: $150 - $300
• Injectors Failure: – Description/Symptoms: Engine misfires, rough idling, loss of power. – Solution: Replace faulty injectors. – Estimated Cost to Fix: $600 - $1200
• Turbocharger Failure: – Description/Symptoms: Loss of power, whistling or whining noise from the engine. – Solution: Replace turbocharger assembly. – Estimated Cost to Fix: $1500 - $2500
• Recalls: NHTSA ID: 10V669000 (Fuel Filter Housing Crack)

3.0L V6 Turbocharged Diesel Engine

• EGR Cooler Failure: – Description/Symptoms: Reduced engine power, check engine light, coolant loss. – Solution: Replace EGR cooler. – Estimated Cost to Fix: $800 - $1500
• Injection Pump Failure: – Description/Symptoms: Engine stalling, hard starting, rough idling. – Solution: Replace injection pump. – Estimated Cost to Fix: $2500 - $4000
• Recalls: NHTSA ID: 11V515000 (Brake Fluid Leak), NHTSA ID: 14V479000 (Fuel Filter Housing Crack)

Transmission

5-Speed Manual Transmission

• Clutch Master Cylinder Failure: – Description/Symptoms: Difficult or impossible to shift gears, clutch pedal feels spongy or soft. – Solution: Replace clutch master cylinder. – Estimated Cost to Fix: $200 - $400
• Transmission Mount Failure: – Description/Symptoms: Excessive vibration, difficulty shifting gears. – Solution: Replace transmission mounts. – Estimated Cost to Fix: $150 - $300
• Recalls: None Found

5-Speed Automatic Transmission

• Torque Converter Failure: – Description/Symptoms: Loss of power, shuddering or slipping during acceleration. – Solution: Replace torque converter. – Estimated Cost to Fix: $1000 - $2000
• Transmission Fluid Leak: – Description/Symptoms: Leaking transmission fluid, visible on the ground or transmission underside. – Solution: Repair or replace leaking components. – Estimated Cost to Fix: $100 - $500+
• Recalls: None Found

6-Speed Manual Transmission

• No Issues Found

Suspension

• Front Suspension Noise: – Description/Symptoms: Squeaking or rattling noises from the front suspension. – Solution: Inspect and replace worn or damaged suspension components. – Estimated Cost to Fix: $50 - $300
• Rear Suspension Sagging: – Description/Symptoms: Vehicle leans to one side, poor vehicle handling. – Solution: Replace worn or damaged leaf springs or shocks. – Estimated Cost to Fix: $500 - $1000

Electrical

• Alternator Failure: – Description/Symptoms: Dimming headlights, electrical system malfunctions. – Solution: Replace alternator. – Estimated Cost to Fix: $400 - $600
• Battery Discharge: – Description/Symptoms: Battery fails to hold a charge, vehicle fails to start. – Solution: Inspect and repair electrical system components, replace battery if necessary. – Estimated Cost to Fix: $100 - $500+

Exterior

• Rear Door Hinge Failure: – Description/Symptoms: Rear doors sagging or difficult to open/close. – Solution: Replace worn or damaged hinges. – Estimated Cost to Fix: $200 - $400
• Side Mirror Vibration: – Description/Symptoms: Side mirrors vibrate excessively while driving. – Solution: Adjust or replace side mirrors. – Estimated Cost to Fix: $50 - $150

Interior

• Seat Fabric Durability: – Description/Symptoms: Seats tear or wear prematurely. – Solution: Replace seat covers or upholstery. – Estimated Cost to Fix: $50 - $500+
• Interior Trim Panel Noise: – Description/Symptoms: Rattling or squeaking noises from interior trim panels. – Solution: Inspect and secure loose panels, replace if necessary. – Estimated Cost to Fix: $50 - $200

Summary: The 2004 Dodge Sprinter 2500 is generally a reliable van but it does have its share of potential issues. The engine and transmission components can experience costly failures, especially with the 3.0L V6 diesel engine. The suspension and electrical systems can also have issues, but they are typically less expensive to fix. Interior issues are mostly related to durability and comfort, and are not major concerns. Overall, the Sprinter 2500 is a capable van, but potential buyers should be aware of its potential issues before making a purchase.