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Where are you buying new ECM’s from that have the least amount of issues? Are any new aftermarket available or is it a reman only type deal?
I don't believe you can buy new ones, anywhere.
Most of them that you get from FLAPS (and I believe Ford themselves at this point) are handled by Cardone for the most part, and their quality control is *meh*. There are a couple other places that are rebuilding them.
But I've had generally good luck with the FLAPS honoring the warranty and swapping them out, if I get a bad one, sometimes it just takes a try or two.
That's your cheapest option, if you need an ECM.
Personally, if it's a truck I planned on keeping for a good long time, I'd probably just spend the extra money on a PiMPx, for the tunability.