Mark,
That's about the same write up I gave the customer. His comment was "Fix It". The customer has a modest budget, so fix it I will! I'll post back with what I end up doing. For the time being, I'm going to disable EGR, disable ESC, inspect injectors (maybe some OEM numbers are on the injectors?), check timing, and check, fuel pressure. I'll start with a modified stock tune (7.4 engine parameters / 5.7 liter 700R4 parameters),and go from there. I have a vacuum referened fuel pressure regulator in reserve, if needed to fix the rich idle / lean upper RPM. It's going to be a long weekend.

I've had good results increasing BPW to about 145 on some '7747 applications.

dave w