Many of us have our speedo calibrated various ways.. Mine is done via GPS and SGI-5, and "dead on" is between two settings, so I went with the one that reports mileage a little short. With our stock speedos indicating a little fast, mine now reports closer to actual speed.
Trust me, I couldn't believe I hit high 15s with AC at 70 on one tank.. but the next one was all-freeway, GPS running the entire time to verify distance, and even topped up to the cap to avoid spout-stop error. 15.4. Outside of the actual off-roading, my worst tank that whole trip was 14.2. Headwind. I even have a second trip a few months apart to the same area with very similar results.
I attribute it to the high tire pressure, part-time kit (more on this in a bit), all new plugs/wires/filter, it being a 94 (seem to run leaner), maybe even the 0w-40 oil (100c viscosity is closer to a 30wt)... actually maybe not. Second trip was with 5w-40 diesel oil.
On the part-time.. same truck, same plugs/wires/fuel/etc, same run, same lift, same tires (though less pressure.. closer to 32), stock bumpers, no second battery, no winch, no sliders (so truck significantly lighter).. 12.5 on the identical freeway trip when full-time AWD.
So apparently a bit more pressure and part-time kit added 2mpg freeway, despite the few hundred # of steel/battery/winch and new front bumper being significantly worse from an aerodynamics standpoint. Though on that, I'm only running a low 2" lift, which probably helps.
Basically, my experience is that part-time DEFINITELY makes a difference, despite what (many) people on this board have posted. Which just makes sense, to me.
All of that said.. I think @LS1FJ40 needs to check condition of the catalysts. Would a bore-scope fit into an O2 sensor hole and turn backward to have a look?