@thorny - sorry to hear about the problems mate. I had similar issues with my SX2 in that I tried what everyone was telling me and to no avail. It turned out to be a combination of two things for me - far too long ackermann, and too much camber.
Re: your question about rear toe in. I ran 3 degree toe-in at a track on Friday (this was too much) so going to return to my normal 2 degree.
Im guessing that when you say 3mm and 1mm you are talking about the washers. This shouldnt be anywhere close to allowing the driveshafts to pop out so something is very wrong there Im guessing - and this might be whats giving you some problems.
I know its frustrating but keep at it - and use oOple alot - there are so many really helpful, knowledgeable guys on here that are willing to help.
Good luck!
