🚨 Diagnostic Profile
Vehicle Make: Dodge
Description: Auto Shutdown (ASD) Relay Control Circuit Open Or Shorted. The powertrain control module (PCM) has detected an electrical fault in the control circuit that energizes the ASD relay, which supplies fuel pump and ignition coil power on many Dodge platforms.
🚨 Repair Difficulty Tier
Tier: [Intermediate]
Diagnosis requires a digital multimeter, a scan tool capable of reading live PCM data, and basic familiarity with relay circuit testing. The physical relay replacement is straightforward, but locating an open or shorted wire may require wiring diagram interpretation.
🛠️ Resolution Steps
Step 1: Preliminary Inspection
- Verify battery voltage and charging system output with the engine off and running.
- Scan all modules for stored and pending DTCs, and record freeze frame data.
- Visually inspect the ASD relay location (typically in the underhood Power Distribution Center/fuse-relay box, confirm orientation against the PDC lid diagram as relay placement varies by model year and platform) for corrosion, burnt terminals, or loose connectors.
- Inspect the relay socket and harness connector for pin spread, backed-out terminals, or moisture intrusion.
- Check the main power and ground distribution points feeding the relay for corrosion or looseness.
Step 2: Diagnostic Verification
- Confirm relay coil resistance and terminal continuity against specifications in the service information, or substitute a known-good relay of identical part number/type to confirm the condition.
- Measure control circuit voltage at the relay socket with the key on: this is a PCM-switched ground-side control circuit on most Dodge ASD systems, so expect to see either battery voltage present at the coil feed terminal with the ground-side circuit floating near battery voltage until the PCM pulls it low, or a near-zero/grounded reading when the PCM commands the relay on — compare readings against a verified known-good reference circuit rather than an assumed fixed value.
- Check the control circuit for an open by measuring resistance end to end with the harness disconnected at both the relay and the PCM connector: a reading of near-zero ohms (continuity) confirms an intact circuit, while an infinite or very high reading confirms an open.
- Check the control circuit for a short to ground or short to voltage with the PCM disconnected and the relay removed: resistance to chassis ground should read as an open circuit (infinite resistance); any continuity to ground indicates a short to ground, and any voltage present with the key off indicates a short to a powered circuit.
- Verify PCM ground circuits for continuity to chassis/engine ground (should read near-zero ohms) and confirm PCM power feed voltage at the connector matches battery voltage with the key on, using a verified known-good ground reference.
- Use an active test (Actuator Test/Relay Control on the scan tool) to command the ASD relay on and off while back-probing the control circuit with the multimeter, confirming the voltage toggles state in response to each command.
Step 3: Resolution & Reset Process
- Repair any open, short, or damaged wiring section using OEM-equivalent gauge wire and approved heat-shrink solder splice or crimp-and-seal methods; avoid butt connectors in high-vibration underhood areas.
- Replace the ASD relay only if coil or contact testing confirms failure, or if relay substitution resolves the fault.
- Clean all connector terminals with electrical contact cleaner and apply dielectric grease to the relay socket and harness connector upon reassembly.
- Clear all DTCs with the scan tool and perform a key-on, engine-off cycle to allow the PCM to re-evaluate the circuit.
- Start the engine, verify the fault does not return, and perform a road test or OEM-specified drive cycle to allow PCM monitors to run and confirm readiness.
- Recheck for pending or stored codes after the drive cycle using the scan tool to confirm the repair is complete and no intermittent fault remains.
📦 Parts, Labor, and Budget Estimates
Required Components/Software:
- ASD relay (standard Bosch-style 5-pin micro relay commonly used across Dodge/Chrysler platforms; confirm exact OEM part number via VIN lookup at a dealer parts counter or parts catalog, as it varies by model year and engine)
- Wiring repair kit: OEM-gauge primary wire, heat-shrink solder splices or crimp connectors, weatherproof connector pins/terminals as needed
- Dielectric grease and electrical contact cleaner
- Scan tool with bi-directional/active test capability (factory-level tool such as Chrysler wiTECH preferred for full PCM data access and relay actuator tests; aftermarket bi-directional scan tools are often sufficient for basic verification)
- Digital multimeter (capable of accurate low-resistance and voltage drop testing)
Average Component Price:
- ASD relay: approximately $15–$45 (OEM) or $8–$20 (quality aftermarket equivalent)
- Wiring and connector repair kit (splices, terminals, loom tape): approximately $15–$60 depending on repair scope
- Total parts estimate: approximately $25–$100 for a relay-only fix; $50–$150 if wiring repair is required
Estimated Labor Hours:
- Diagnostic time: approximately 0.5–1.5 shop hours for relay/circuit verification; up to 2.0–3.0 hours if an intermittent wiring fault requires extended wiggle-testing or harness tracing
- Repair time: approximately 0.2–0.3 hours for relay replacement only; 0.5–1.5 hours for a localized wiring/connector repair; additional time required if the harness repair is located in a difficult-to-access area
- Total labor estimate: approximately 0.7–3.0 hours combined diagnostic and repair time, with shop labor rates typically ranging $100–$170 per hour depending on region, resulting in a total labor cost of roughly $70–$510
- Note: No dealer module programming is typically required for this repair unless PCM replacement is necessary due to confirmed internal driver circuit failure, in which case PCM programming/VIN configuration charges of approximately $150–$300 would apply in addition to the PCM hardware cost