Interesting info.

I am curious as well how the one pump lasted so long but the other only a few weeks if that.
You said that you hook the evap system back up to pass smog, was that around the same time frame you installed the new pump?

I remember reading a thread sometime last year where some one had actually cut a square section of Toyota tank, pulled out the baffle, cut a match hole in a new tank, put the baffle in, and then welded in the Toyota tank section so that everything essentially stayed stock.

I will try to search around to see if they have had any issues with the set up, this may be an option?

I am unsure how the module in the ford works vs. the for baffle, maybe if the module detects the fuel flowing about in the tank and slows down the pump when it gets air over fuel into it?