What diagnostic tools do you have available? Are you able to look at aldl data? How does it idle with the TPS unplugged? Possibly a bad wire going to the TPS? Should be a reference 5vlt reference ground, and signal between 0 and 5vlts based on throttle positions. 5vlt full throttle.
Temp sender for gauge is separate from the one the ECU uses. Gauge sender should be on the head on the driver's side.
For your codes I would start by looking at your egr vacuum line, then check out your egr.
Had no idea about the cat and o2 difference, almost sounds like a Cali vs Fed emissions deal. Never really looked at a 305, I always assumed it was setup the same as the 350.
Hp not making it available to change those parameters doesn't surprise me
I usually start with a good thorough visual inspection of all vacuum lines and connectors.
p0102 is Mass airflow sensor low, could be signal dropping off from it.
Is there an oiled air filter?
common issue is over oiling them and the oil contaminants the MAF.
you can get a can of mass...
Have you tried the repository on HP tuners website?
There are .bin files available at gearhead-efi.com, but you won't be able to use HP to load them.
You should be able to make a 5.7 file work fairly easy, IMHO all you would need to change is the displacement, as long as the 5.7 and 5.0use...
Mine did just fine in od with 18k gross ( counting truck ) data logs showed normal tranny temps. Converter locked doesn't heat ATF up that much, unlocked torque manipulation does.
With 3.73 and small tires I couldn't imagine driving over 65 in 3rd for sustained periods, with 265 tires, that's...
For what it's worth, the calibration engineer I had correspondence with told me that at the proving grounds the 4l80e could handle locked up tc in OD pulling 18k up a grade, all the other autos I know of all say to tow with od off, 4l60 included. IMHO as long as you have enough power to pull...
Here is 4.10 245/75-16 vs
3.73 225/75-16
Looks like you are still a little lower than me about 4 or 5 mph at cruising rpm.
I couldn't imagine towing in 3rd unless I couldn't maintain speed in 4th.
You might get better mpg in 4th.
3k is fine as long as you have good oil. Lots of opinions on that, but I had a GM calibration engineer tell me that the best thing to run in these is 10w30, and that aligns with what my own research is. That's what I personally run, and I don't change my oil on intervals, I check my oil...
Towing in OD won't hurt the 4l80. It's made for it. It even has a lower OD ratio than the 60e. What is hard on them is slow shifts in second gear for creature comfort, and pulling a long grade with torque converter unlocked, both can be solved with programming.
What size tires you run...