IMO 3-inch diameter piping is too large for the 5.3L. Yes it does not sound like much of any increase, but the frictional losses are exponential regarding changes in diameter. The flow is now turbulent (versus laminar) and now the exhaust velocity decreases which reduces exhaust scavenging. A tune would definitely help to reduce this and address the annoying 6-speed.
In my opinion better to stick with stock piping diameter and just change the muffler then tune. Hopefully one of the tuners will chime in. If you get the EFI tuner you can change back to stock when you visit the dealer.
Ok just a question here as I'm trying to learn. If the tube diameter is too large for the engine, then why would Magnaflow make and market the product?? As I stated before I had the same kit, as well as a CAI, on a 2009 Tahoe 5.3L and had no problems.
I have talked with Magnaflow about the problem. They have never had any complaints about this kind of situations with this vehicle. I even asked if there was a kit more suited for the engine and vehicle. They assured me I had the right kit for the application. But they were very helpful in trying to determine the problem. Of coarse they say its not related to exhaust. I also double checked to make sure their muffler was non-directional(thinking maybe it was installed backwards).
I have a dyno-tune scheduled for next Tuesday at a very reputable local shop. I stopped by there today and talked with him for quite a while. He's certain he can resolve the issue. The vehicle will be checked bumper to bumper and by diagnostic computers before any tuning is started. I will keep you all posted.
Thanks for the advise, opinions and help as I'm trying to sort thru this mess. I learn something new every time I get on the site.