fuel levers have been anywhere from empty enough for the low fuel light to come on, to full tank. but i usually keep tank over 1/2 full.

 

follow up:
they spent three days troubleshooting it on and off, and not only is the PCM bad, but it also took out one of the new cats.
we are waiting for parts.
more to follow as i get updates from the shop.

 

it has now been 2 months with no change. 94 warm up cycles and 1300 miles later and still can not set readiness for 02 sensors or 02 heaters.
stopped by the ford dealer and they said there is nothing wrong with it, just run it. they had basically the same truck last year that took 9 months to set readiness for 02 sensors and 02 heaters.
local cop told me to scrape the failed inspection sticker off and run it cause all the cops in town know me and will not bother me.

i still want to get it figured out though.
three people told me i can force readiness with forscan, but could not tell me how to do it.