No mangle rules just dynamic queues from pppoe server, CPU 40- 60% approx (with V5.20 graphing is not working so hard to tell CPU load ?)I really don't think so.
433AH is a pretty quick board.
How many mangle rules, queues, etc?
What is your CPU usage?
Ok will test DBii F50NJust upgrade the cards to DBii F50N cards.
CPU will handle it