Grannysshifting, your pm box is full.

Need more than 3 limit!

Thanks to all for the inputs... Looks like I'l have to rebuild my upper.
Questions for a Bravo X 2006:
Should I change all the bearings, shims, races that I found in there?
I would have the pinion gear pre loaded to the specs but If I replace with exact same original parts to rebuild the unit, will I have to re-shim and do other adjustments before torquing with the spanner wrench to get the pinion gear back in? It's really confusing in the manual...

The cone clutch is just a few hundred dollars. If you are in the drive, go ahead and replace it too.

Planing on it... It was actually the reason i opened the upper for. Then I had the surprise with the gears. I wonder if with the exception of the pinion gear that has to be preloaded if there is any other special adjustments involved when replacing all the other parts in the upper? In the manual, when they put the pinion shaft back in before torquing with the spanner wrench, they seem to f@! around with shimming and adjustements in order the get the pinion gear at the right place.

Anytime you replace upper gear set, it should be shimmed to specs to get the proper gear lash. Not all gears sets are identical to each other, hence the setup needs to be checked. If the thrust bearings and inner bearings have no damage they can be reused. Look at them with a strong magnifying glass to check the needles. If any metal particles come out of them, then replace them. If the inner ones have metal in them or don't roll smoothly then replace them. Shims are subject to damage also. Check them, flip them over, but a lot times they need to be replaced to get the gear lash to come in.

Hope that helps.
Dick