Well, finally some good news. The truck is running good once again, and hopefully for more than a week this time. The long story short is to never, ever think you are saving any money by buying aftermarket parts. The long and the short of all my problems has been a poorly made aftermarket timing gear set. I have basically lost the last 2 months of what little free time I actually have, to save about $450 in parts cost.
After the second timing set proved to run even worse than the first, I left work early tonight with a dual channel Fluke oscilliscope and a plan to check my entire harness or change out the tone ring. I tore out the entire wiring harness for inspection first because i came across so many incidences where the harness was the issue, I just had to eliminate it. After 2 hours of not finding anything, I bit the bullet and yanked the valve cover and very carefully swapped the cam sprocket with the tone ring for the OEM one off my spare motor.
With the OEM tone ring in place, timing verified, and a brand new OEM cam sensor, it fires right up and runs perfectly smooth. I took it for a short drive and it is all there with no stumble or hesitation and no more P1391 code.
I snapped some pics of the oem tone ring against the aftermarket and its no wonder it didn't run right. I wanted to swap them sooner but it would run right some of the time which indicated that it could have been something else. Hindsight is 20/20 though and I am so full of would have, should have thoughts right now I likely won't sleep at all tonight for beating myself up.
I have always said that as long as I learn something at the end of the day, it was not a waste, but this little endeavor has tested my ability to grin and bear it more than anything i have ever been involved with. Partly due to the fact that I have always made good money and never had to sacrifice before, especially on things that matter like a daily driver. I was trying to cut corners to make my accountant (my wife) happy and it bit me in the ass hard. Let this be a lesson to all of you. Some things you just can't cheat. The stress this has caused in my personal life has been far more expensive than the parts ever would have been but I have learned a very valuable lesson that will not be forgotten any time soon.
Here are pics of the first tone wheel compared to an OEM one. OEM on the left, Cheapo on the right.
Here's a couple more of the two cheapo tone wheels. The first on the left, the warranty replacement on the right...The replacement was even poorer quality than the first.