High EGT's

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Should I be able to move the valve (1/4 turn I think) through its full range of motion without disconnecting the linkage?

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Depends how strong you are, It would take a substantial amount of effort. The spring tension on an open valve will be about 10 PSI. That will get progressively higher to about 60 psi when closed. The retaining clip slides straight along the rod to unlock in. I'm not at the shop to look at one but I believe you slide it toward the pedestal to unlock it. You don't have to worry about losing it. It won't fall off the rod.

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I can't get good enough grip, position or leverage trying to reach under turbo without removing other parts. I could probably move it through its full range of motion, (assuming it's not mechanically stuck) if it wasn't on the truck. I would feel a lot better if I could positively say I was 100% sure that the EBPV was not slightly closed. I may have to dig in to it to prove or disprove this. If I’m going to dig in to it, my feeling is I might as well gut it. This would probably be an opportune time to upgrade the down pipe as well. I would like to hear any thoughts people may have on this strategy. Anything else I should do while I’m there?

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I wouldn't necessarily look for cooling fin damage. I would look for stuff in them blocking the airflow. One of the most extreme examples I've ever seen was an 18 wheeler that had hit a swarm of Honey Bees.

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I didn't see much debris stuck in the fins. Did see where fins are slightly bent in several locations from minor impacts with foreign matter. Those fins bend pretty easy. With highway speeds of 75 mph, I don't think it would take much more than a large bug to do this. After you mentioned checking the CAC, I was thinking this could possibly restrict air flow enough to cause problems.

Update:

CAC pulled and cleaned with soapy water. Cleaned out all cooling fins with a garden hose. CAC pipes cleaned as well. CCV mod completed. New set of boots arrived but bottom Y pipe boots and passenger CAC boot were the wrong size. Apparently there is a difference between the early and late 99 boots. Make sure you verify when ordering. I should have the rest of the correct sized boots by my days off next week. I changed out the boots that were correct size and cleaned the heck out of the old boots with brake cleaner. Found a very bad v bend in the round passengers side flange next to the valve cover for the lower Y pipe boot. Can anyone tell me what the technical name for this part is? Don’t see how I could have possibly been making a sealed connection there. I got some round pipe to match the inside and outside dimensions of that flange. Cut in to half circles; put one on the inside and outside of the v bend while squeezing with a pair of vise grips. This did a pretty good job of taking the dent out. Hopefully I can get a good seal now. The truck seems to make boost much faster now. While driving unloaded, the EGT’s don’t appear to be rising quite as fast and are definitely lower at cruising speeds on the highway. Did not have time to pull the 5th wheel with it yet. Will be changing out the rest of the boots later this week.

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I suspect that an overtightened boot to the intake manifold air plenums deformed the inlet and that was the source of your major boost leak.

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Could be but after I straightened it, I put the boot on with the y pipe removed and tightened the heck out of the clamp. The inlet appeared to stay round. I'll be back in there later this week when I get the rest of the boots and I can take another look.

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Might consider replacing them with cast or billet intake plenums. Several vendors (BDP etc) offer them.

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Thanks for the Info. I'll have to do some price checking.

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I pull about the same weight trailer, but mine is a bumper pull. The 2000 didn't have a Cat, and I too have the AIS/BTM combo with Zoodad mod, and before tunes I could only get to 15 lbs of boost, 18.5 psi without tunes is very rare, sure the boost gauge is right?

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I was pulling the 5th wheel, on the highway, up a hill, and doing somewhere around 70 mph in traffic. Couldn't really concentrate too long on the gauge so maybe I miss read it. I have had AE hooked up for test runs and seen 17.4 PSI boost. For some reason that is the highest range my AE software will read. Unloaded yesterday I saw 17+ several times on the analog boost gauge. I'll have to hook AE up again to compare readings.

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The highest temps I ever saw was 1150 pulling some steep, very steep switchbacks, now with Jody's tunes I have a lot more power and haven't seen 1100 even when really getting on it on some 6-8% grades. I think you are asking to much. 1100 degrees is nothing, these trucks can run all day at 1225, 1250 and depending on who you talk to even higher. If all you are seeing is 1100 be happy, call Jody and get some towing tunes, this will help EGT's and really get the boost up there.

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I called Jody last Wednesday and ordered some towing tunes. They were a Fathers day present from me to my self. I was hoping I’d have them by Fathers day. Didn’t happen but I’m sure they will be here early this week. Can’t wait to try them.