2004.5 problem areas and fixes

[gerry]

I am looking very seriously at replacing my trusty old 2001 with a 2004. 5 3500 and wondered where the trouble areas were. I'm very familiar with the 24v areas ie. lift pumps, 53 blocks and vp44s but don't know much about later 5. 9s. I do know the engine is a 325hp model I'm looking at. Thanks, Gerry

 

[p-Bar]

well see if the the canister mounted fuel pump was replaced with a intake retro. See if the the trans hunts between 1st and second drive slow up a steep hill increase speed till it starts to shift into second it may vascillate between first and second. The cab lights will probably leak unless they were upgraded. Some of the trannys pop out of park so always set the park brake the fix by Chrysler was a joke. the tail light sockets have disimilar metals on them so the burned out light indicator will light up . Chrysler has upgraded this now of course we have to pay. That's it for now

 

[rscurtis]

Personally, I'd look for an '03 or '04 with the 305 engine. It has simpler programming, no cat, better fuel economy, and can benefit from extended oil change intervals. The addition of an aftermarket turbo and manifold will give you the missing HP and an additional fuel economy benefit that you'll never see with the 325 HP engine.

 

[gerry]

Personally, I'd look for an '03 or '04 with the 305 engine. It has simpler programming, no cat, better fuel economy, and can benefit from extended oil change intervals. The addition of an aftermarket turbo and manifold will give you the missing HP and an additional fuel economy benefit that you'll never see with the 325 HP engine.

Is the milage worse for towing, empty or both? How much? I really don't care much for empty because I use mainly for towing.

 

[rscurtis]

I can't give you a good answer to that question. The only real towing I did with my truck was in April 2010 to pick up a Gravely tractor in a 5X12 U-haul trailer. It still got 20MPG on that trip.

 

[Regcabguy]

I'd just look for a 2003-2007 5. 9 that's got moderate miles,fairly stock with complete service records. If the owner doesn't have records,walk away.

 

[p-Bar]

I think the problem is that we are seeing so many with with fairly high miles that you almost have to plan on a rebuild motor sorta like buying a VW bug dad always said plan on a rebuild. Still think the 03 HO motor is the best

 

[TDemoraes]

P-Bar I would like to know how you fix the burn light indicator when it lights up. I have a 2003 that is having the same problem, the burn light indicator comes on at times. If you could help in any way it would be appreciated.



'03 2500 long wheel base, 2 wheel drive, stock all the way, 70,000 miles, lazy truck never worked one day in its life

 

[TDemoraes]

P-Bar I would like to know how you fix the burn light indicator when it lights up. I have a 2003 that is having the same problem, the burn light indicator comes on at times. If you could help in any way it would be appreciated.



'03 2500 long wheel base, 2 wheel drive, stock all the way, 70,000 miles, lazy truck never worked one day in its life

 

[p-Bar]

P-Bar I would like to know how you fix the burn light indicator when it lights up. I have a 2003 that is having the same problem, the burn light indicator comes on at times. If you could help in any way it would be appreciated.



'03 2500 long wheel base, 2 wheel drive, stock all the way, 70,000 miles, lazy truck never worked one day in its life

What has seemed to help is to pull the bulbs in and look at the sockets and see if there is some discoloration which is a sign of arcing and not making a good connection use some fine steelwool to polish it then put some dialectric grease on the connection. You can purchase that at Home Depot in the electrical department. Good luck

 

[MConyers]

My '03 and my cousins '03 both had the lamp out failure from a young age. He replaced the bulbs once, then the next time gently bent out the contacts on the bulbs, that has lasted him for the last 5 years.



I just reseated mine a few times, that lasted until i traded the truck a year later on a '04. 5.



This was only on the tail lamps for our trucks.



I owned the '04. 5 about 4 years and had 2 issues with it (fixed under warranty):

- leaking clearance lamp

- blew up the steering pump, it gave me notice but still sucks when you lose power steering and brakes at the same time



Only plus I had for a '04 over '03 is the headrests in the back of a quad cab.



I was looking for an '06 or '07 5. 9, G56 Mega 4x4 for quite a while before I broke down and bought a new one (hope it is as reliable as the '04. 5).

 

[RKerner]

• Door wire harnesses - replaced all door harnesses except for the driver's door.
  
• Passenger front door window switch - needs to be exercised regularly or else it only works from the driver's side.
  
• wipers will either work intermittently or the intermittent won't work. sometimes a stalk switch fixes it or sometimes the wiper module fixes it.
  
• injectors had some infant mortality but they should have all been replaced by now.
  
• headlight bulbs can be finicky - had one go out and took 3 replacements to keep the bulb indicator off.
  
• steering linkage may be covered under a "silent" recall. got mine replaced but one tie rod end is wearing faster than the old ones.
  
• PS pumps seem to be a bit weak - first one broke the mainshaft, the second one was walking the pulley outward.
  
• brake hydroboost/master cylinder might get "sticky" as in the brake lights stay on sometimes - dealer said it will take $1100 in parts to fix it.
  

got 127k on mine and won't upgrade anytime soon, unless you give me an offer I can't refuse.

 

[BIGNASTY]

04.5

I have a 04. 5 HO 2500 and actually the only thing that I HAD to fix was the funky fuel lift pump. I have left it stock as I dont need 500 HP at the ground in this small of a truck and I think that is one of the reasons that I havent had to fix a bunch of things. I use snake oil in my fuel and have added better fuel and oil filtration other than that the 98,500 miles on it have been trouble free. But one last thing IM A FANITIC ABOUT SIRVECING THE TRUCK.