04 Silverado Truck will not start (crank) in the mornings. After about a minute 30 of jacking with the key it finally starts. New ignition housing, 2 new ignition switches, key and tumbler, cleaned all ground’s except the one from back of block to firewall. I couldn’t get to it. I have a new starter. I really do not think that’s it but I have ran out of options. I took it to a 11 year veteran Chevrolet mechanic who now owns his own shop. He changed ignition switch also and it only does it in the morning now. I can’t figure it out for the life of me.

 

Welcome to the forum.

When you say it won't start, is it turning over and just not firing?

I'm moving your post to the Silverado section where it will get more views and possible answers. This is just the Welcome New Member section of the forum that is not meant to be used for problem solving.

 

Have you inspected wires in the steering column? Could be a slight break in one of them. With enough messing around with the key, it could potentially be wiggling the wire into position to work. What also comes to mind is the shifter (assuming column shift). I don't believe the engine will crank at all if it's not in Park. Now by "in Park", I don't mean the indicator states as such, as I'm sure it's in Park as far as the transmission is concerned, but perhaps some electrical connection telling the ECM that it's in Park is at fault. You might consider checking out wiring for that to see if that's the issue as well. When this mechanic swapped things out, he may have bumped something that helped partially alleviate the issue.

 

Been having the same problem intermittently with my 2004 Suburban for months. Swapped starter, battery, and starter relay, which worked for 3 weeks until yesterday and today.

My problem seems to center on the starter relay area. It's sending the code to crank but signal doesn't get through until I mess with the terminal connections of the starter relay in the underhood electrical center fuse block and get them to slightly spark, then the starter cranks and starts for several cycles. I also have a secondary current draw that takes my batter voltage down to 12.1 volts or so.

Been watching related videos and found two that traced this problem to the fuse block -- internal connection error. Here's the video, hope it helps.