Got some good news. I got a call from Roush (I'll not mention names as he's not been mentioned here before). I described the problem to him on the phone, all the way back to the bad mechanical adjustments that had been done (including the bell crank turnbuckles all the way in) and the root cause of the bad throttle position cable. Then the attempts at tuning on the dyno and still "missing" at 4500RPM, and backfiring when I let off the accel.
I questioned the
oil capacity and Todd and he are pretty sure that it is the original
oil pan, so the 11qt fill is probably wrong. That probably explains the
oil overflow but not the rest of it.
He said they would look at the DFI controller but we both believe - he based on his talk with Todd - that the original installation was sloppy and needs to be cleaned up. If it gets toofar and it looks like a swap of the controller is needed we'll switch to their new (simpler to manage and install - fewer wires) DFI controller.
Anyway, I've placed the order with Intercity to ship it back, and should have a scheduled pick up date soon.
In reality I don't expect to have it back before much of the summer season is over.