grab the PROM from the 5.7. you will need it. I also assume you are using the TBI from the 350 with the 350 injectors? I think 305 and 350 trucks used the same ECM, just different PROMs.
I'd keep the 350 stock cam. straying too far results in the need to get a custom tune.
EGR is closed at idle. so unplugging the vac to EGR doesn't do anything at idle. manually opening the EGR, or using a mityvac to open the EGR, should cause it to bog at idle.
I'd hit up the fuel and emissions manual and look at the "symptom" charts for backfire and misfire. I think section 2...
uh- I did read it. this is what you wrote -
"It doesnt take much heat to operate the O2S, they all should have internal heaters. Is the heater working?"
i don't consider the exhaust heat to be an "internal heater" but I am also not a drunk mechanic. maybe that's where I am missing...
I just used LED on headlights and auxillary fog lights where it really matters and kept the rest incandescent. I have seen too many threads about issues LEDs in turn signals to even want to try it elsewhere
just move the throttle all the way to WOT at the tbi. if the cable is tight like a guitar string, you should be fine. it may click a time or too if it was too tight before as it properly adjusts
that black thing a few inches past the cable end is the clip. reattach it....quickly.
TV cable is very important to the transmission functioning and not burning up. that's why I asked about it back in post 22,658 of this thread.
If you're running good as is, and with the limitations of TBI, I'd just leave the exhaust manifolds on there. Headers wont add much from what I've read. Look at a new exhaust coming off the manifolds if you need a new exhaust system.
TPS position only affects TCC lockup on a 4L60 with TBI. Shifts are very much controlled by the TV cable. I'd ask the shop if they made any adjustments to it when they tightened the intake manifold.
remove the vertical piece on the ductwork that you can see under the dash. then you can watch the door operations and look for issues before diving deeper.