yeah maybe its TM.

Might also be the 60-1 -- don't you have a 5.7? I'd think a 60-1 would be too small for that mill.

 

This is something to check. Its very easy to thread that banjo fitting in too far and pinch or tear the diaphram on the wastegate.
Don't go without the crush washer that comes with the TiAL wastegate because it will let you thread it in too far and it will rub on the diapham too.
Just a couple of things to look at.
Open up that cap and see if you are getting little marks on the diaphram where that screw hits it. The banjo fitting was a little too long on my original WG and STS sent me a whole new unit because of the tear in the diaphram.
I'm speaking of the banjo fitting on the side of the WG, not the end.
If the diaphram is torn you have issues to resolve.

 

I've tried two WG's as well. Both do the same thing. I'm working on getting a .81 a/r and will try that. Sometimes I wonder if the .96 is just a tad large for keeping my engine happy with boost.

 

The engine in your truck is really not that much bigger than mine, I think the Chevy kit has the same base turbo and associated components.
I think the turbo can supply you with all the boost you need up to a certain HP range, then a bigger one may be neded for more volume.
I have seen boost spikes with a faulty WG that pegged my gauge, it goes up to 15psi and it was hammered to the stop!!
What bar spring is in your WG?
The only time I have ever seen boost creep was in the colder months when the WG was malfunctioning.
I'm thinking its something else besides the hard parts.
To me this sounds like the tune or something Dodge has built into the system to save the trans from too much power....TRQ management.
I am not reall familiar with the Tuning of Dodge vehicles, has there been some kind of breakthrough in the last year as far as tuning goes because I had always heard that the tuning was what was holding the Dodge guys back.
What, or who do you use for your tuning?
Just curious.

 

I do my own tuning. I've replaced my factory injectors with 55# units. I've replaced my 1 bar map sensor with a 2 bar and use an smt6 to control it all. I've tried all kinds of tuning methods, high map voltage or reduced map voltage, meth injection, no meth, reduced timing, increased timing...

I currently have a 3.6psi wg spring in and have changed to 5.8psi to see if the "lighter" 3.6 spring was being affected by backpressure.

I'm gonna get a .81 a/r housing from STS (test unit). I've always been told that the lower the a/r, the more low end boost you get but less top end. I can understand that in high boost applications. But if I'm looking at 8 to 12psi of boost, what's the .81 or .89 housing gonna do vs. .96 in the top end? Less hp per psi? Will it struggle at 10psi?

 

Are yo able to reduce or eliminate TQ.MNG. from your tune?
If not can you see how much the factory settings pull from the tune to decrease trans power?
After getting my trans done to handle the power increase of the Turbo I had Allen Nelson remove all of the TQ. MNG. from my tune.

 

I think what you trade is spool time for psi off the top end, but should not be a problem for 10psi. I'm still wondering if the compressor is too small for the hemi's cubes?

 

I have snipped my tq management wire so from a shifting point of view, tq management is gone. However, there are a couple of other tq management functions outside of shifting.

I pulled my wg today and studied the diaphram and checked for rubbing on the fitting. Everything looks good. I went ahead and pulled my filter and gave it a good cleaning just in case it has some flow issues restricting me on the upper rpms. I'll check that out tomorrow.

 

On the GMs, TM can actually close the throttle blade and retards timing (grrr) which is why it gets turned off so often.

Maybe the Dodge OS has something similar?

 

It seems I have an excuse/answer for everything, but I do appreciate the feedback. I have an autoxray scanner that monitors everything on the truck. Even when the pcm isn't retarding timing and my throttle position still registers a WOT condition, boost drops.

I was told the .81 a/r housing would also raise EGT's some. Anybody played with smaller A/R's and notice EGT changes? .81 might be too small. I might hunt down a .89 or .91 to try. The .81 is free and a direct fit so I guess it would be easy enough to swap to see if this is even a direction I need to go down for the solution.