Called Transgo today before I dropped the pan, the tech on hand nailed my problem. He said they have had a few problems with the boost valve popping out. When you look into the bore you see a groove but thats not for the ring clip its farther down., and that there is only 100 thousanths clearance, it was tight! So I dropped the pan and low and behold the boost valve is
bathing. What a chore that is putting it in from underneath!
91 Silverado 2005 5.3 ,transgo hd2, Yank2600, Nelson Tune, 3" exhaust, 4-6 drop
2004 Silverado crewcab 5.3 3'' Magnaflow exhaust