Which parts fail
Components named in complaints (headlights, tail lights, turn signals, interior lights).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Dodge Ram 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
On this model, as well as others within a close date range, the forward control module(fcm) shuts off the headlights if it recognizes any disruption in current or ground. This has happened to me about 4 times in the last year and causes a safety concern as the only thing I can do is turn on my brights, which in turn blinds other drivers. The module is located outboard of the fuse box, located above driver side wheel well in the engine compartment. Price is usually around $400 for part, then I have to take it to somebody to have it keyed to my computer for another $100-200. There is no variable as to when it happens, sometimes while in motion, sometimes while stationary.
Tl* the contact owns a 2004 Dodge Ram 2500. While operating the vehicle, both the high beam and low beam headlights would not illuminate. Also, the rear driver's side window would not operate due to damaged electrical wires located in the driver side door panel. The contact indicated that the wires became damaged by opening and closing the doors. In addition, while at a stop light, the vehicle momentarily experienced unintended acceleration. The cause of the failures was not diagnosed. The vehicle was not repaired. The local dealer (jerry wood Dodge in salisbury, nc) and the manufacturer were notified of the failures. The failure mileage was 195,000.
While driving at night both headlights went out. Replaced bulbs headlights would not come back on. Was told that the front control module was bad. Replaced front control module with a new one. 13 months later now the horn will stop working a couple times a week a mouth very intermittent. Turn signals are intermittent also. Engine will not start all the time just cranks tell you cycle the key. Was told this is all related to another front control module going bad. New module is not under warranty anymore. I fill this is a safety issue . I have heard lots of complaints from other Dodge Ram owners about the same issues
Tl* the contact owns a 2004 Dodge Ram 2500. The contact stated that the running lights failed to illuminate. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 130,000.
Either the power control module (fusebox) failed or the forward control module did (the part under the fusebox. Several lighting groups will go out even when driving down the road, including headlights. I have no doubt this is a safety hazard to have your headlights become unfunctional at night while driving. How I know it is a big issue that Dodge has not felt necessary to issue a safety recall is because when I went to order the part I was told it is on at least a 6 week back order. There are so many owners having the same problem they can't make them fast enough to keep up. So that means 2004 Dodge Ram pickup owners have to let their vehicles sit in the garage for 6 weeks as it is not safe to drive them until they receive the part. I have had similar problems with Dodge and until they are forced by you to issue a safety recall they won't. …
Headlights malfunctioned attributed to the front control module according to Chrysler star representative.this is a "known" problem that the dealer was not prepared or able to diagnose. According to Chrysler star support desk the front control module p/n 56051036ad has a known problem. I was only able to find this out after calling Chrysler customer service and insisting that the dealer call their star support desk and open an incident. The rep at the support desk immediately told the service tech that the front control module had a known problem. The intermittent failure created a safety hazard on the highway by not functioning at all or malfunctioning. Lights on truck can fail at any time headlights,taillights,brake lights because of this front control module there is no backup on the system when it fails. …
My 2004 Dodge Ram 2500 does not have working running lights. I cannot safely drive the vehicle at night. Per the Dodge dealer, they have diagnosed it as part number 68005476aa (fuse box/power control module). The part is, and has been, on national back order for a very long time. Apparently, this is a wide spread problem that others are experiencing in varying electrical/lighting ways. The lack of improper or non-working lights poses a safety issue. The non availability of parts makes a perfectly good vehicle non-drivable.
I have a 2004 Dodge Ram 2500 with a 6 speed manual transmission. The sensor in my manual transmission that turns on my reverse lights failed. I replaced my sensor and the problem was solved. I am concerned because not only can I not see when backing up, other drivers are not alerted to my vehicle moving in reverse which could be dangerous to myself and others. There seem to be quite a few of these failures because the part was on backorder from the manufacturer.
Tl* the contact owns a 2004 Dodge Ram 25000. The contact stated at the directional signals and the windshield wiper failed. When the right directional signals was activated, the left directional would flash and the windshield wiper would not clear the windshield. The vehicle was taken to the dealer where the dealer. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 70,000 and the current mileage was 136,000.
On our 2004 Dodge Ram 2500 slt crew cab. The turn signal will sometimes intermittently do the exact opposite of the direction you choose and when this happens the headlights will not go bright if you have it on dim and the windshield wipers will not work as we found out shortly after we bought the truck on a rainy day. It appears it is all controlled from one location on the steering wheel column.
Headlight complaints in other Ram 2500 years
Frequently asked questions
How common are headlight problems on the 2004 Dodge Ram 2500?
NHTSA has 26 complaints about the lights of the 2004 Dodge Ram 2500, 4% of the model year's 582 complaints. The component named most often is headlights (3 mentions).
Is there a recall for 2004 Dodge Ram 2500 headlight problems?
No. NHTSA lists no lights recall for the 2004 Dodge Ram 2500, though it has 6 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Dodge Ram 2500 headlight problems start?
Half of the complaints with a recorded mileage happened before about 109,000 miles, and 9% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.