5 psi is low, you should get 7 to 9. I would still try disconnecting and plugging the vac lines from the boost control actuator to see what boost you get. My bet is you will pick up 2 to 3 psi. Again, if you do this, make sure it is only for a short run and you reconnect the lines right away.

The tech guys on here recommend not going smaller than 3.5". Do a search on "pully size" and you will see a lot of information on this.

It may be hanging up just short of the actuator arm stop. If it is, I will have to work with it some more. I had some trouble with it returning all the way back. I will check into it when I work on my A/c next weekend. My A/C is losing charge in about 3 days. I pray the leak is under the hood and not in the evaporator core. I will be looking for that leak monday. A/C is one of my specialties but pulling a dash to fix it sucks for anybody..lol. Thanks for the tips

When you are in there getting things all loosened up with the WD40, don't forget to work on the pivot pin that the boost control actuator connects to. The pivot pin passes through the throttle body, and should be lubed at the front of the TB and at the rear until it rotates freely.