Alright as a update, i just got done putting about 1000 miles on in the last 24 hrs..

before leaving i made my own design of a mech wastegate after not really understanding why the ones everyone linked me to were going a different direction etc etc..

Going down the highway i'm between 4-6lbs of boost with the cruise on.. again 1 ton crew cab 2wd 4.10 gears, 4 people in it, loaded bed with gear etc, 20ft car hauler.. If i floored it the boost would creep to about 9psi tops usually around 7-8 tops but you really really needed load and a big hill to even get near 9psi.

On a side note i got just over 17 mpg going 70-75 the entire trip..

The problems....

The boost gauge line is getting to be full of oil (the clear line running front the plenum.. its driled and tapped about 2 inches from the silicon coupler.)... the turbo has a really liquidy black stuff on the base of it when i was looking over it before i installed the new mech. wastegate.

Another problem, like 3 times i got a SES light going up a hill which i thought was over boost but its never under wide open throttle, and the first two times it was higher boost 5 psi + but the last time it was only at 3-4psi... once it comes on it stays on until you restard the truck.. haven't gotten a chance to check the code though.

Now as far as pulling, the last 200 miles i've been loaded with 75% of a wrangler, (body tub, frame etc) then i've got two dana axles on the trailer, 4 people, crew cab long bed.. and gear.. and i had no problems just setting the cruise at 70-75 and pulling up even steep hills etc.. however getting up to speed to merge with a total lenght of almost 50 ft... thats another story..

Hey turbochevy, just a couple of uninformed observations on your problems. IMO your turbo seals are hammered and you need a fooler or a chip to stop the ses lights. Your home made turbo master needs to be adjusted for more tention on the spring to hold the wastegate closed to get more boost. Based on your mpg's, you're not putting more fuel in (more fuel-more power) so your power is down. With the load you're pulling (12K ?) you aren't going to make any 10 sec quarter's. Give the old girl some help and she'll treat you right. Check it out and good luck.

drop the dana axles unless it's a 60 front and a 70 rear to save weight and get rid of your friends, get the codes and then diagnose, Oh and you have durmax tow with that.

well i am starting agree that the seals in the turbo might be going bad, i was down after only 500-800 miles through the mountains today, i had to put in half quart maybe less to get it back to full.

I have the wastegate set to about 7psi max now and 3-4 during highway speed and ran all day without any check engine lights.

after about 300 miles, loaded i got a low 16 mpg on flat ground and about 100 of that was in city.. williamsburg..what a riot 40+ft of truck and trailer... trying to pull into the christmas stores...

The truck did start running amazing through the mountains and fully loaded was able to start off at 65 and easily pull to 75-80mph on the worest inclines.. as long as i didn't start out at like 1800 rpm at the base of the hill then i was really draggin *** for a minute.

As far as the jeep stuff, its a set of matching MINT dana 44's high steer flat top knuckles and with low miles.. off a 90 waggy. Should work nicley in place of my 130+K D30 front thats been getting BEATEN on 33X12.50s with 4.10 gears behind a built 4.0L...

Before discounting turbo seals, go through the CDR thread in FAQ, turbos & intakes will always have some oil, a bad CDR can allow for excessive crankcase venting resulting in situations similar to what you report. Have you scanned the PCM or self checked to know what codes are causing the SES to come on, it may or may not be boost related, and unless boost level is problem fooling probably will not resolve your coding issue.

Since you are OBD-1 you can use a paperclip to pull codes, procedure is outlined in FAQ, only problem with clip method is that it only allows viewing of active codes currently present, Auto zone & others will read codes for free, and their scanners also have the ability sometimes to read intermittent codes stored in the event history portion of the PCM, that collects one off events

See after taking a closer look at the turbo there was a puddle (very small) in the inlet of the turbo.. liquidy watery black probably oil.. I am starting to think that its something to do with the mess of a crank case vent also.

If ya think the CDR is messed, try cleaning it out:

http://blog.heathdiesel.com/2006/04/cdr-crankcase-depression-regulator.html