JoshH has a post on here with 2005 TSB info
As per the instructions provided...can anyone provide me with the details of the TSB listed in his attached word document?
It is 04-06-04-001C
Backgrounder - My 2005 LLY 2500HD has a hesitation / backfire ~ once or up to 3 times in rapid succession when accelerating under medium to heavy medium acceleration and is accompanied by a loud bang or popping sound that appears to come from the engine compartment somewhere. There are no codes...and no SES light. It does not do it all the time. It will do it when stock, or with a tuner or smartbox - usually more significant and frequent when modified from stock with a tuner. Also on my boost gauge - then needle appears to bounce when this happens. It happens at around 10 to 13 psi boost. and bounces about 2 psi on the gauge when it hesitates. It happens only when accelerating, so I've been ruling out "turbo bark".
I used to use a van aaken 0/70/110 HP smartbox E and ran it on the 70 HP setting. I now have a predator on the 65HP setting and I have stopped using it as well for the time being. Currently I am back to stock as I seem to have the least issues with it.

I have searched relentlessly on the internet using the symtoms I've experienced as search words. I found that GM's TSB # 3450 may apply to what I am experiencing for an issue. It is also listed as NHTSA No 10017090 Duramax Hesitation or Backfire. If someone has access to provide details on any or all of the above TSB's, I'd really appreciate it.

If someone has had a similar problem - I'd sure like to hear from you too...!

Thanks!

Here you go:
Engine Controls - Intermittent Driveability Conditions

Bulletin No.: 04-06-04-001C
Date: November 28, 2006
TECHNICAL
Subject:
LB7 LBZ LLY LMM - Intermittent Driveability Conditions Such as No Crank, Crank But No Start, Hard to Start, MIL/SES, Hesitation, Lack of Power, Surge, Misfire, Fuel Knock, No Serial Data Communication, IPC Indicates No Oil Pressure, DTCs Set (Inspect Connection/Replace Connector Bodies)

Models:
2001-2007 Chevrolet Silverado Pickups
2006-2007 Chevrolet Express Vans
2003-2007 Chevrolet Kodiak C4500/C5500 Series
2001-2007 GMC Sierra Pickups
2006-2007 GMC Savana Vans
2003-2007 GMC TopKick C4500/C5500 Series

with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, 6, D - RPOs LB7, LLY, LMM, LBZ)
Supercede:
This bulletin is being revised to update the model years and add Condition and Correction content. Please discard Corporate Bulletin Number 04-06-04-001B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various intermittent driveability conditions:
No crank
Crank but no start
Hard to start
MIL/SES Illuminated with EGR (http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OD~N/0/108596970/108596971/110536644/110536650/34853741/34857029/34857699/34858149) DTCs, cam sensor DTCs, fuel pressure (http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OD~N/0/108596970/108596971/110536644/110536650/34853741/100411974/34853743/58828685) DTCs, turbocharger (http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OD~N/0/108596970/108596971/110536644/110536650/34853741/34857029/34858641/56213502) DTCs, injection circuit DTCs
Hesitation
Lack of power
Surge
Misfire
Fuel knock
No serial data communication
IPC indicates no oil pressure
Various engine faults or DTCs may occur due to backed out pins in the following main engine harness connectors:
C107 and C118 (38-way) Engine Harness to the Engine Chassis Harness Connector
C108 and C119 (24-way) Engine Harness to the Engine Chassis Harness Connector
Cause
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P4R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161313
The main engine to chassis connectors utilize a plastic tab formed into the connector body as a terminal lock (5). If a terminal lock (5) is damaged or broken, the terminal (1, 4) will be pushed partially out of the connector body (2, 3) during assembly and will make poor or no contact with its mating terminal. Various and intermittent engine control faults may occur.
Correction
When reconnecting the engine to chassis connectors, slide the Primary Lock Reinforcement partially out of the male side connectors to support the ends of the male pins upon installation. Guide the chassis side connectors straight into the engine connectors when using the lever lock to avoid terminal misalignment. Failure to do so may cause terminal lock breakage.
Inspect the terminals in the male and female sides of the connectors for broken terminal locks by removing the terminal position assurance (TPA) comb at the back of the connector (if equipped) and gently pushing and pulling on the wire in question. If the wire moves within the connector and does not lock into position, the connector body should be replaced.
Connector Location
The following connectors are all located at the engine harness to engine chassis harness that is mounted to the top of the driver side valve cover.
C107 and C118 (38-way) Engine Harness to the Engine Chassis Harness Connector
C108 and C119 (24-way) Engine Harness to the Engine Chassis Harness Connector
If an illustration is needed to locate the connector in question, please refer to SI and build your vehicle publication to view. Then select the following areas:
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P4R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161314
Body
Wiring Systems
Component Location
Master Electrical Component List
Connector Components
Terminal Position Assurance (TPA) (C107 and C118 only)
Cable Seal
Female Terminal
Lever Lock
Connector Body - Female
Connector Seal

Primary Lock Reinforcement (PLR) - Female (C108 and C119 24-way connectors only)
Primary Lock Reinforcement (PLR) - Male (C108 and C119 24-way connectors only)
Connector Body - Male
Male Terminal
Cable Seal
Terminal Position Assurance (TPA) (If equipped)

The 6.6L diesel engine utilizes a 24-way and a 38-way Packard Lever Lock GT Series sealed connector for the engine to chassis connection. Connector components can be serviced using the J 38125 Terminal Kit. Connector bodies are available through GMSPO.
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P4R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161315
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P4R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161316

These components are available from the J 38125 Terminal Kit.
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P3R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161317
Parts Information
Warranty Information
http://www.alldatadiy.com/alldata/AFI~V13797782~C40208~R0~OB0~P3R0H~N/0/108596970/108596971/110536644/110536650/34853741/34850750/42063452/122648681/126161312/126161318

I thought i had one where the egr was the issue...?? as well as a recal....

Thanks Buddyboy.

For some reason, the images in your post seem a little off topic and they change every time I open them. Is this happening for anyone else?

Your right - the images are changing!

I'll try posting some other way.

See MS Word.doc attached

Thanks!