Sounds like vacum leak on back of intake if it is a 2.o split port motor there is a elbow that fails look close at back of motor it is a 10 dollar part here is the part number from ford YS4Z-6A614-BA connector let me know if it fixes it
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check fuel pressure should be 36 - 43 psi sound like problem could be fuel pump, first what i would do change fuel filter,replaced fuel pump relay check fuel pump fuse make sure it is in place tight. code scan car if you see check engine light flash.another thing cause stalling contaminated gasoline.
Have you tried removing the chip, reseting the pcm, then test drive without the chip, I do not work on diesels but I know I have had some 5.0s with compatibility problems with performance chips, for some reason on select cars the emissions system would through a fit and make the car run like crud with the chip in ran fine with it out although they accused it ran fine for a few months with the chip. if you havent you might try this just to see
The catalitic converter is a mechanical device , it simply converts harmful emissions into water/vapour.
The 02 sensor if faulty would put the engine management light on. If the 02 sensor has been faulty for sometime it could tell the ECU to supply the wrong amount of fuel to the engine which in turn would eventually damage the catalitic convertor.
So you may have to change both in the end, but first I would check out the 02 sensor and replace if required.
Try a tank of supreme gas, plus a can of SEAFOAM in the gas tank.After running about a half of this tank out. Pull positive post off the battery for about 1-minute. This will reset computer, and it might clean up the fuel problems that you are having. If it keeps on, change the O2-sensor out and do the above steps again.