Happened a couple times and eventually started by moving the small relays around, we thought. Last time it happened we swapped relays 32 and 33 in the long fuse box in the engine compartment. 32 is a starter relay and 33 is ETAX. First time someone at the church got it started by swapping these relays around, there are 4 in a row.

Doesn't look like it's intermittent now, can't get it to start at all. Checked for spark to the plugs, isn't there. Main clue seems to be that "it hesitates to crank for about 1/2 second when trying to start" unless we stop at ignition on before bumping the starter. Never does that when it's working. Check Engine light wasn't on when we got it running before but the 'Service 4WD Soon' light is on. I replaced relays 32 and 33 (p/n 4671168) but didn't help. Battery seemed ok but the green dot wasn't up so replaced it.

I only have the Haynes manual for this Durango, have the Factory service manual for the 2000 Durango.

Went out and tried the key for engine codes: 688-ASD relay sense low.
522-Oil pressure low, check gauges.
2112-?
5.7 Hemi, 100k miles.
Appreciate any ideas.

 

I was going to tell you to go buy new relays, but I see you already replaced them both. Back trace the circuit to see where it goes and where it starts then test it section by section. This is going to be alot of fun for you.

 

The starter and battery connections should be checked to rule them out,
FF

 

Probably the pause when turning the ignition key to start is the best indicator of the problem. Does anyone have the factory service manual, that could look it up?

 

The solenoid on the starter may be shot,
FF

 

Still trying to use my 2000 Durango Factory Service Manual. Found one for the 2004 but it's 4 volume set and the cheapest I found is $127. Probably get it sometime.

Found that the PCM normally puts the ground on #85 pin of the Auto Shutdown Relay. So grounded that pin and the car starts. So have to find out why the PCM is angry and not wanting the engine to start.

Checked the codes again after engine was running:
1120 doesn't exist
685 ASD circuit
688 ASD circuit - relay sense circuit low
522 Oil pressure voltage low
2112 doesn't exist

 

Found two wires corroded about one foot from the ASD relay. One was the wire the PCM grounds the relay to engage it. Other wire put out the "Service 4WD" light that's been on for a while. Cut the corrosion out and soldered the wire. Everyone says the salt from the roads had to have done it. Was the car with the power spray underneath, then coated the wires from top and bottom with battery protect spray, that stuff that coats everything red. Durango is working good!

 

Great, glad everything worked out and the starter was fine as I was wrong,
FF