I made
some sort of progress so I guess I should use it to update my thread. A few weeks ago I had it tuned by Futral Motorsports mainly just to disable AFM and the rear O2 sensors. Included in the package were a few other small tweaks such as trans line pressure, reduction of Torque Management and removed speed limiter. It wasn't a full-on power tune where they tweak the fuel and timing tables, datalog, tweak, etc. which costs $400+. This was just a $150 tune to kill AFM and allow me to run long tube headers with catless Y-pipe. I'll worry about a full tune when I have something worth tuning, something other than the current 182K-mile 5.3.
Since having AFM disabled, the low-RPM rattle in V4 mode is gone and my fuel mileage is averaging .5 MPG lower than before. At $2.40 per gallon, my original 16.2 MPG calculates to 14.8 cents per mile. Without AFM, a mile now costs me 15.3 cents. That's an increase of half a cent per mile and ten cents per average 20-gallon fill-up (I don't run the tank bone dry between fill-ups).
I can afford the extra $1.00 a month to possibly prevent me from having to spend thousands of dollars to repair or replace the engine. Also, if disabling AFM reduces the ~1 quart per month oil consumption even a fraction of a quart, then the savings in the oil costs alone would make up for the drop in MPG in multiples.
Pertinent pic for mildly dramatic effect:
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