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I've seen this discussion before, a search may yield more info. I think the concensus was that the backlash is a non critical spec. (not a fact just speculation). I believe this to be true from my own experience. I took apart my 2.7 RS replica engine after 80k miles and the aluminum gear showed obvious wear. The teeth were asymetrical and had worn about .005" or more. The back lash of course was very large. I put in a new 0 gear (that's all that's available) and the backlash went to just about zero. I think the most important thing to look at is the wear on the aluminum gear. If the gear looks ok then reuse it. If not then replace it. It wasn't that expensive. By the way I was supposed to use a 1 gear due to having a 1 case and 0 steel gear. I found that the 0 gear was big enough and I think a 1 gear would have been binding.
-Andy
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72 Carrera RS replica, Spec 911 racer
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