Ok, here is the final chapter in this saga - just received an email from TDC saying the following -
"Sorry for the trouble. I should be the one thanking you for your patience.
What's frustrating for us is that we've had great success with Hilux models that have had the 3-pin connectors. I'm confident now that the anomaly of your vehicle requiring a 6-pin connector indicates that the ECU programming, tolerances, and signal ranges are far different than other Hilux models. Remember, your vehicle was the first Hilux that we have come across that required a 6-pin connector, instead of the usual 3-pin connector. Because you were feeling a difference in power at a setting of "9" with the original unit, it seems very likely that your vehicle has a limiter (maybe a torque limiter) that was preventing the faster acceleration. The most recent unit we sent you was programmed to work with a more limited signal range, and we were hoping that your vehicle's ECU program settings would be consistent with those signals. I won't be using this hypothesis anymore.
Unfortunately, the only way we can remedy this problem is to take some measurements and conduct a few tests with your vehicle in our shop facilities, and this is obviously impossible.
If you return the most recent unit we sent you, we'll give you a full refund. I apologize for the inconvenience, but this is all we can offer for the time being. "
Therfore Ill be getting my money back after all the to'ing and fro'ing and the upgraded Toyota ECU looks like a tougher nut to crack than the pre-07 models were.
Guess in the end what you can take from this is that pre-07 Hilux TDC Powerbox's work fine but if you have the 6pin connector 07 onwards hilux's you cannot use this unit and must look elswhere instead.
I think Ill be looking into an exhaust for the hilux once the refund is in.
atleast it made for a great read for you guys....bummer for me thou