I've changed the timing on trucks at least a dozen times and to my knowledge, none have ever slipped. They are all local and I'd have heard about it if they had. Like DBraunig, I always clean it 3 times with brake cleaner and compressed air.
As to the torque on the nut, I'd be real nervous of going over the spec of 145 lbs. I talked to Joe Donnelly about this spec at one time and as I remember (its been a couple of years) he said he's seen the threads on the shaft stripped at 160 lbs. In any case, its not necessary if the shaft and the mating surface of the gear is properly cleaned.
Oh, and for what it's worth, I've never used a new nut or washer. I've changed the timing on mine 3 or 4 times, and Oilburner on this site (a personal friend) has done his at least that many. Same nut and washer - no problem. BUT, change it if you feel better. They are cheap insurance.
-Jay