[Wayne Maybury]

Unless you are absolutely sure you have found the problem, I would suggest a test drive after fixing or changing something rather than tearing everthing apart at one shot. If you change many things at the same time (without finding clear evidence of the problem), there is no way of knowing what the problem was so you don't know what to look for if it ever happens again later on.

It would appear that you have a 7000 RPM rev limiter chip in your box. An MSD 6AL box comes with several chips including a 7000. The MSD boxes generate some heat on their own and do not like to be over-heated so they should be located in a cool area, preferably not under the hood and certainly not right beside the headers.

Wayne