front axle end float clearance issue

[crash520]

So, I have rebuilt my 99 GU hubs, swivel bearings, the whole shebang. Did the left hand axle end float clearence check, I have 1.5mm clips in there at the moment and I can fit .85mm between the clip and the stub axle housing, i recalled previously this had some clearance so it looked normal for what it is, I do need to put larger clips in the left hand side or replace the bronze spacer I guess.

Now the fun part, the right side, in went the axle, fitted up the stub housing etc, I have like 2mm clearance between the clip and the housing!!! see the photo. now, the other thing is, I cant push the axle in to close up that gap, I can imagine if the bronze spacer was badly worn I would see this much end float gap but right now, I have no end float as such, just a huge gap.
56435

[the evil twin]

Whwn you rebuilt the hubs did you happen to change from Auto to Man or change any of the shims

[crash520]

Nope, has manual engaging hubs, just did bearings and seals, it may have had this when I took it apart, didnt really take much notice. That said, the right hand axle does not have anywhere the same seal wear on the shaft as the left indicating a newer axle, AND the right axle was covered in a white grease including inside the hub, full. The left axle just had what i expected to see, grease packed CV joint only and with normal type grease. So, the right hand axle may have been replaced and may not be the correct one???

[crash520]

Bump, anyone else got any idea??