1. I just want to make sure I understand correctly what you are experiencing. Are you saying that: a) before adding XSESSION="Gnome" to /etc/env.d/90xsession your PC
never switched to TTY7 (i.e. the problem was definitely deterministic); b) after adding XESESSION="Gnome" to /etc/env.d/90xsession your PC
sometimes switches to TTY7 (i.e. the problem is definitely intermittent)?
2. Does you kernel boot line in /boot/grub/grub.conf look similar to that shown in the excerpt from my grub.conf below?:
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title=Sabayon Linux x86-64 (2.6.29-sabayon)
root (hd0,2)
kernel /kernel-genkernel-x86_64-2.6.29-sabayon root=/dev/ram0 ramdisk=8192 real_root=/dev/sda6 quiet init=/linuxrc splash=silent,theme:sabayon vga=791 CONSOLE=/dev/tty1 resume=swap:/dev/sda7
initrd /initramfs-genkernel-x86_64-2.6.29-sabayon
3. Try moving xdm to the default runlevel, because I still think this might be a cause (you can, of course, move it back again afterwards if it does not solve the problem):
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rc-update del xdm boot && rc-update add xdm default
4. Can you also post your /etc/rc.conf file in this thread, please?
5. Have a look through /var/log/rc.log to see if you can spot anything.