After months of intermittent no start conditions which resulted in multiple flatbed rides to the mechanic (out of warranty) and one fuel pump driver module later which was not the fix, i have finally narrowed the problem to the fusebox in the engine compartment. Once a week my truck will crank but not start. If i tap on all the fuses and hit the the lid real hard a few times, it will start. None of the fuses are blown, and ive swapped all the relays to no avail. Anybody know why banging on the fusebox works?

 

look into ur fuel pump fuse.. mine did the same fuse was good until it started to melt..

 

sounds like there might be a loose wire behind your fusebox.

 

Thats more what i was thinking. Im just not sure how to take the fusebox out to be able to check. Its the box on top of the radiator on the 5.4 2009. And it only effects startup. The fuel pump will never shut off while driving.