You'll have to forgive me for a lack of detail because shortly after my trouble started I parked the truck for 9 months or so and only began driving it again recently.

I have an 04 1500 QC Hemi 4x4 w/ 55000 miles
After reading that other owners had done the same without trouble, I bought an ebay CAI and installed it. It seemed to increase a mpg or so and offer a perceived increase in hp (could easily have been placebo).
I normally wouldn't go the cheap route but I hadn't heard any negative reviews and I was looking for a little extra mileage.

If my memory serves, it took a couple weeks but eventually the CEL appeared and the truck would hesitate upon acceleration. Since this was the only change I made I immediately put things back to stock but nothing changed.

The best way I can describe it... If I accelerate normally (or slowly) the truck will vary between not responding at all and surging forward. I essentially have to give it more throttle than necessary from a stop to keep it from doing this. So basically, if the truck isn't accelerating (if it is under partial throttle, say, driving a flat road at a constant 30 mph) it goes from nearly dying to surging. And often, when approaching a stop under very little acceleration, it will die.
If the battery is disconnected and reconnected the CEL goes off (as it should) and for the next several hours of driving it stays off and the truck drives normally. Then the CEL comes back on and the symptoms begin again. Things aren't that bad initially, in fact it takes several days/weeks for it to get bad enough to where the engine dies as it used to.

At this point I'm convinced that the cheapy CAI I installed (polished aluminum w/ blue "rubber" joints) had some chemical in the filter that ruined a sensor somewhere.
I replaced the IAT a sensor after removing the CAI to no avail.

If no one can give me an answer I'll go to a dealer but I'm pretty mechanically inclined* so I'd prefer to do it myself if it's an obvious fix.

I've given more guidance on forums than I'll likely ever receive so, in advance, I know there are those on here with vast knowledge and I appreciate any help you can give and I'll gladly pay it forward.


*I've done brakes, shocks, struts, power steering pumps, axle seals, u-joints, etc. (not all on this truck obviously :P)

 

This has nothing to do with the CAI. The CEL isn't a magic light. It's there to indicate a problem via a code associated with it. Go to the auto parts store and have someone read the code. Then come back and tell us what it is.

 

Yep, impossible to diagnose without the CEL, could very well be as simple as the EGR valve as these would be it's symptoms. If you've never replaced it at 55k miles, that would be my guess.

GET THE CODE READ...

 

i agree and its free at autozone

 

it is the EGR valve... my dodge, same year and model as yours... as well as my 04 durango LTD with the 5.7 hemi has the same symptons as your described..
Simply change it out and it will be fine!

 

Look at that! You guys are awesome! That is why these forums are good....someone, somewhere has probably gone through the same thing you are going through.....

 

Get that code read, then there will be no need for speculating about what the problem is.