As noted on the web page, the exact feeler thickness is not terribly important. I have to stack up two leaves on my feeler gauge. But the idea of that test is the with the throttle fully closed, you get one reading and with it open a bit, you get another reading. Whether that happens at 0.5mm or 1.0mm or someplace in between probably makes little difference. The fact that it happens is what is important.

So it sounds like the TPS itself is fine, you might check that the signlas from it are getting back to the ECU properly. But it may be something else that is causing the problem. I think when you disconnect the TPS, the ECU goes into open loop mode and maybe some of the other bad inputs are ignored along with the missing TPS.

http://www.4crawler.com/4x4/CheapTricks/AFM/index.shtml