Many of the sensors are set to no MIL light in Engine Diagnostics in the tune. You will not know you have failures. The exhaust manifold protection is turned off as well as catalyst protection and component protection in the tune. Did you modify your tune or was it this way when you started? When you stated dyno, I assume someone modified your tune? Appears after dyno tuning, parts of the tune were not turned back on. If you modified your tune, I would go back to your factory tune and start over. Find out how it runs on the factory tune. Hopefully you copied and saved it. If you don't have a factory tune, you can possibly find one in the repository or somewhere listed in one of the posts that you can compare yours too and get it back as close to factory as you can. I don't work on Ford's , so I don't know what some of these factory settings are. I would have to compare myself with a known good factory tune and make those changes. If you did make changes, you need to decide what you are trying to accomplish and then just modify one thing at a time and check the results. Key on will not give accurate 02 readings and should not ever show ready. The engine has to be running and go to closed loop - CL. You risk damaging the cats if they aren't damaged already. I would not continue to drive set up this way. No telling what else you may damage engine wise.