2004 Dodge Sprinter 3500 Service and Repair Manual

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Fits the 2004 Sprinter 3500 — Base Standard Cargo Van 3-Door ·
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2004 Dodge Sprinter 3500 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

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

20121109Component: ENGINE

WHEN I AM DRIVING A FREEWAY SPEED THIS VEHICLE LOSES POWER AND THE SPEED DROPS TO ABOUT 40 MPH. THIS HAPPENS RANDOMLY. I HAVE HAD THIS TRUCK INTO THE DEALER SEVERAL TIMES. THEY HAVE REPLACED THE MAIN

20090626Component: POWER TRAIN

TURBO CHARGER RESONATOR,BOOST HOSES, INTAKE AIR TEMP SENSOR CLIPS, LOCKING CLAMP AT INTAKE MANIFOLD FOR BOOST/CHARGE AIR HOSE RETAINER. FAILURE OF EITHER ONE OF THESE COMPONENTS (TOO OFTEN BY MY EXPER

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