PCM Problems?

[William K. Mcdorman]

I have a 2002 explorer 4dr XLT with the E 4.0L. The problems I am having:
1. The fuel gauge will randomly stop working and will return if I shut off the vehicle and restart

2. The idle is rough. when first started it will run smooth at around 1100rpm until it slows down then it is rough and random(there is no rhythm like it is hunting its just rough)

3. some times it will crank and not start. however I can cycle the key 2-3 times rapidly and then it will start right up.
there are no codes except the occasional catalytic converter code because I do not have any.

The following have been replaced:
1. Fuel Pump
2. Fuel Filter
3. Air Filter
4. Plugs and wires
5. Coil Pack
6. TPS Sensor
7. MAF Sensor
8. Fuel Injectors
9. Crank Position Sensor
10. Alternator
11. Idler arm, pulley and belt
12. Water Pump
13. Fuel pump relay
14. O2 Sensors

I was trying to hit all the common failure points because we are about to take a long trip with a camper and I do not want to be stranded 1000 miles from home.

other things I have replaced include
all wheel bearings and axels, all brakes and front end parts and shocks and struts and u-joints, new tires

Transmission was rebuilt 40k miles ago. 180k total miles engine runs strong with no smoke (when it will start lol)

I am looking for guidance on my current problems and any pointers for other things to check before our trip.

 

[William K. Mcdorman]

Here is a picture of my Baby

 

[William K. Mcdorman]

Ok broke down and took the truck to my local ford dealer. They told me the intake was warped and leaking and the idle air valve was bad and my fuel system needed cleaning and quoted me $1100. I told them it has a new fuel system(pump, filter and injectors all new) and I would replace the 2 parts myself($329 in parts) with a lifetime warranty. So now my question would be is there a reason not to do away with the egr valve. would that not lower my intake temps and prevent the new intake from warping?

 

[Mbrooks420]

You have new o2 sensors, but no cats?

 

[William K. Mcdorman]

Well I have the stock exhaust minus the flow restrictions before the muffler

 

[Mbrooks420]

Not familiar with flow restrictions, unless you mean rear cats.

 

[imp]

Without cats (or with very old ones), DTCs will be thrown constantly related to position 2 (downstream) "O2 sensor heater", totally unrelated to heater problems. imp

 

[William K. Mcdorman]

Lol all the cats were gutted because I could not afford to replace them at the time

 

[96firephoenix]

The idle is rough. ........catalytic converter code because I do not have any.

Fix this with Cats. The ones one RockAuto are cheap and reliable.