Be carefull with boost bypass valve. Its expensive!!
 

I was moving the position of the bypass valve as shown in some articles that describe how to do this and it broke off the mounting plate. I tried to stick it back on with crazy glue but it came off, and then tried epoxy. It lasted longer but came off again and this time one of the vacuum outlets broke off as well.
No problem, I thought I would just buy a new one, looked like maybe a $30.00 part.
Wrong!! $350.00 from the dealer! I asked a buddy who can get parts at close to cost and it was still $196.00 but I had to buy it.
When I got the new part and compared the two I found that mine had internal leaks anyway.
You can check to see if the part is working by sucking on the vacuum inlets by mouth. If you suck on one, it will pull the actuator rod in and hold it there. If you suck on the other it will prevent the rod from being pushed in. This is on the new part.
Please excuse the crude method, but it works.
Also check for vacuum leaks in this area. I found several small hoses and elbows with split ends and a large T fitting that leaked.
One question. The actuator rod is pulled all the way in at idle in park and jumps out when you rev the engine. Is this normal?

Sounds like normal, predictable operation to me (including that last part).

Ouch, that hurt, but thankfully yours is the first failure of the actuator we've ever had posted here. It's usually the very affordable BCS. Great work on nailing this down, and thanks for the technical test procedure! :lol: