We tried a product similar to NoAlox from I.C.E. that is a conductive anti-oxidant with aluminum filings. It didn't help. Haven't tried switching out the pcm yet...I guess they don't make new ones anymore, just the reman's according to the dealership. Also, heat/warping could still cause problems on your replacement part in the future.
To temporarily fix the problem until our pcm part arrives, we re-routed the windshield washer fluid over the pcm with small holes to spray fluid on the pcm while driving to cool it down. I know it sounds redneck but we drove it for 500 miles roundtrip without an incident here in Arizona where the temps can be brutal. We are still replacing the pcm and considering installing a fan or air vent to help control the problem in the future.
Thanks for the info everyone and keeping us posted!
