What size tires are you running?I am having the same exact issue... driving down streets I feel I have no issues, but once im on the highway, the acceleration is sluggish and hard to keep the speed up. Flooring it at best getting 40mph... and the slightest road incline (seriously 1-2degrees) the OD kicks in at 3500-3800 RPMs. After reading so many posts... I ordered all new catalytic converter to see if it solves my issue.