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I ran into this exact situation last year while rebuilding a 2.7L. I was about .002 thou out of spec as per a dial indicator and human eyesight. I ended up runnnin' it with no issues of noise.
Like John said, once the cases are botled together, that lash will more than likely decrease. Also, with heat, that alu gear will expand some and help you out even more!
Now glue that thing together already!!!
Chris
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