2004 Dodge Sprinter 2500 Service and Repair Manual

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Covers all 2004 Sprinter 2500 trims — Base Standard Cargo Van 3-Door, Base Standard Passenger Van 3-Door ·
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2004 Dodge Sprinter 2500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Standard Cargo Van 3-Door
  • Base Standard Passenger Van 3-Door

Engines covered

  • 2.7L 2687CC 165Cu. In. l5 DIESEL DOHC Turbocharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #08V33900024/07/2008Component: STEERING:COLUMN

SPRINTER IS RECALLING 10 MY 2001-2006 DODGE AND FREIGHTLINER 2500 AND 3500 VEHICLES. THE WELDING SEAM BETWEEN THE BRACKET AND STEERING COLUMN OF AFFECTED SPARE PARTS DOES NOT MEET DESIGN SPECIFICATIO

Consequence

THE OPERATOR MAY LOSE STEERING ABILITY OF THE VEHICLE INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL INSPECT AND REPLACE THE STEERING COLUMNS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEG

NHTSA #16V83300017/11/2016Component: ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

Daimler Vans USA, LLC (DVUSA) is recalling certain model year 2003-2006 Dodge and Freightliner Sprinter 2500 and 3500 vans manufactured June 30, 2003, to August 31, 2006. The instrument cluster on th

Consequence

Without the BRAKE lamp illuminating during the vehicle start up bulb-function check, the driver has

Remedy

DVUSA will notify owners, and DVUSA and Dodge dealers will correct the instrument cluster software,

TSB #10221319

Emissions Recall T21 Reprogram Engine Control Unit

TSB #10220935

Emissions Recall T21 Reprogram Engine Control Unit

20230811Component: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCUL

The contact owns a 2004 Dodge Sprinter 2500. The contact stated that while the vehicle was parked in the driveway with the ignition key turned to the off position however, the vehicle remained on, cau

20230811Component: ELECTRICAL SYSTEM:IGNITION

The contact owns a 2004 Dodge Sprinter 2500. The contact stated that while the vehicle was parked in the driveway with the ignition key turned to the off position however, the vehicle remained on, cau

20220805Component: ELECTRICAL SYSTEM

The contact owns a 2004 Dodge Sprinter 2500. The contact stated the backlight of the instrument panel had remained illuminated after the vehicle was turned off, and remained constantly illuminated. Th

20200307Component: ELECTRICAL SYSTEM

THE T21 RECALL HAS COMPLETELY RUINED MY PERFECTLY MAINTAINED AND STABLE WORK VEHICLE. INITIALLY AFTER HAVING THE RECALL DONE IT LEFT MY BATTERY DEAD AS IT LEFT COMPONENTS RUNNING...IT HAS BEEN IN AND

20200307Component: ENGINE

THE T21 RECALL HAS COMPLETELY RUINED MY PERFECTLY MAINTAINED AND STABLE WORK VEHICLE. INITIALLY AFTER HAVING THE RECALL DONE IT LEFT MY BATTERY DEAD AS IT LEFT COMPONENTS RUNNING...IT HAS BEEN IN AND

Showing the 5 most serious of 20 complaints filed with NHTSA.

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