The tunes won't cause a stall. Regardless of who does the tuning, there's nothing in the tuning parameters that says "run for xx amount of minutes and then turn off".

So did you take the black plastic case off and try the chip? I'm betting you will find your problem.

what do you mean? dummify it for me as I am deployed and gotta walk my wife through it

Here's the black plastic case out of the truck:
http://i641.photobucket.com/albums/u...r/DSCN2491.jpg

Here's the case modified to accommodate the chip:
http://i641.photobucket.com/albums/u...r/DSCN2492.jpg

Here's how I've been running my SD trucks for years (excuse the loose tape...it's only there to help when I have the emulator attached for live tuning) and I only use masking tape since I'm constantly changing PCMs and whatnot. You don't NEED the case, but the PCM will rattle around if you don't tape it down:
http://i641.photobucket.com/albums/u...r/DSCN2490.jpg

hmmm and this is a known problem? my wife said my buddy jeff trimmed the black cage some

This is one of the only documented ones, but I have taken countless calls over the last 18 months with this same concern.

Power Hungry Performance Forum

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If your wife is still having problems with the box modified so it's not contacting the chip, then you have a connection issue. You may have to have the contacts on the PCM board re-tinned. This will add material (and important thickness) to the terminals so the chip makes a solid connection. Check out the pictures I posted....

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http://dygytalworld.ehost-services13...e_1280x960.jpg

http://dygytalworld.ehost-services13...e_1280x960.jpg

i will send her pics of the contact area, but the chip is on its way to tony tomorrow morning. how does re-tinning happen and what is the cost involved in re-tinning

Retinning is a fairly simple process with a cheep soldering iron and some rosin core electrical solder. Lay the hot iron on the terminals and feed a little solder into it. It might be good to practice on something that doesn't matter like a broken radio to get the technique down first but it isn't hard.

how much is required to be put back on?

Very little. Don't get too crazy with it.....if the contacts are "built-up" too much, the terminals inside the chip can be damaged.

The pictures I posted are a perfect representation (and no, I didn't do those ones).