The aim of this study was to investigate the interaction between physical form of starter (PFS) and forage source (FS) with free access to forage on feed intake, growth performance, rumen fermentation, blood metabolites and behavioral traits of dairy calves. A total of 48 7-day-old Holstein calves were randomly assigned to one of four treatments in a 2 × 2 factorial arrangement, with FS [alfalfa hay (AH) and wheat straw (WS)] as free-choice supply and PFS diets (cracked vs. steam-flaked) as main effects. Feeding treatments included (1) starter diet with steam flaked corn (SFC) and free access to AH (SFC-AH), (2) starter diet with SFC and free access to WS (SFC-WS), (3) starter diet with cracked corn (CRC) and free access to AH (CRC-AH) and (4) starter diet with CRC and free access to WS (CRC-WS). The calves were weaned on day 58 and remained in the experiment until day 70. All calves had free access to water and starter feed. The results showed that there was no interaction between PFS and FS in terms of starter intake, forage intake, dry matter intake (DMI), average daily gain (ADG), body weight (BW) or feed efficiency (FE). Calves fed CRC consumed more dry matter, TMR and forage than calves fed SFC diets. Regardless of the PFS diet, weaning weight, total weight and total ADG were higher in calves fed WS, while forage intake was higher in calves fed AH. Calves fed CRC-AH had the lowest rumen pH at day 68 compared to the other groups (except SFC-WS at day 70). An interaction between PFS diets and FS affected rumen proportion of propionate on day 35, since calves, which were fed CRC-AH had the highest molar percentage of propionate than calves fed other diets (except for SF-WS). At day 65, calves fed SFC starter feed had higher plasma glucose concentrations than calves fed CRC. It was found that PFS feed and FS had an interaction effect on BUN at day 65, with calves fed CRC-AH having the highest BUN. Compared to the other groups, calves fed CRC-WS had the highest BHB at day 33 and throughout the period (days 35 and 65). An interaction between PFS diets and FS affected lying time and forage eating time, with CRC-AH calves exhibiting the longest lying time and lowest forage eating time. The time spent on NNOB tended to be longer in SFC-fed calves than in CRC-fed calves, regardless of the forage source. Compared to calves fed SFC, calves fed CRC with high levels of fine particles consumed more dry matter, TMR, and forage while spending less time on NNOB. Furthermore, feeding calves chopped WS instead of AH increased weaning weight, total weight, and total ADG, although forage intake was higher in calves fed AH. In summary, a combination of cracked corn starter with free access to wheat straw appears to provide the best growth outcomes for dairy calves.