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1/32" in and out and almost none (a few thousandths?) side to side, if I remember correctly. If you can feel the side to side easily, then it's probably well used up. Almost every one I've seen over 100k were trashed. But, if they aren't touching, and there aren't any wear marks on the fins, or the housing, you could run it but keep an extra close eye on it. However, if you run it at high RPM's, I wouldn't chance it. I have run some that are pretty loose, but not touching, but I don't run them over 2800 rpm's, and usually much lower.
My daily driver had 164k miles on it with active EGR, and it was touching. All the ones I've seen in the 150k range are pretty bad. I think with proper cool down they might last past 200k.
If you run it easy, and take a peak at it once a year for any contact of the fins, you can probably limp one along for a few more years safely.
_________________ 05 CRD: H.D.S2 stat,WW Ironrock trilink&LCA's, OX rear,ARB front, 4.10's, ARB bumper, Suncoast,OME 3.5, JBA UCA,rock rails, Moabs&265/75 Duratracs, GDE tunes ,FFD fan,ARP's, 2 micron fuel, new valves,sasquatch battery tray & grid heater, tensioner relocated Mech fan, VH & AC delete
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