If the DYI transmission fix idea isn't something that you would rather leave to someone else, here are some resources:
See
http://www.ttcautomotive.com/English/onlineorder/product.asp to download a FREE service manual for T5 or Tremec 3550
You will need the Adobe Acrobat viewer which is also a free download –
http://www.adobe.com/products/acrobat/readstep2.html
See
http://www.ddperformance.com/index2.htm for parts
OR
http://www.hanlonmotorsports.com/
A T5 rebuild kit with syncros, bearings and other small parts costs about $160. It does not include any gears or shafts.
There is a video on how to rebuild your T5 or Tremec. If
http://www.hanlonmotorsports.com/ are out of stock see
http://cartapes.com. It costs less than $20, and is worth every penny of it.
I did a Tremec 3550 rebuild, and it wasn't that difficult. The video was an immense help, and I would recommend viewing it. At $20, it will give you an opportunity to look and decide for yourself if you think that it is something you want to try to do.
The tricky part is that you will need some shims to adjust the endplay in the two shafts: the new bearings will change the clearance. There is no way of telling what it will be until you get to the point that it is time to measure and check the clearances. Halon has the individual shims if you can wait for them. If you can't afford the wait, the auto parts store can sell you some shim stock and you can make your own, or have a machine shop make them for you. The shim stock comes in brass (easy to cut) and steel, in varying thicknesses.
Getting the car jacked up high enough to get the trans jack in and out from under the car was somewhat challenging. Since I didn't have a helper, getting the trans out of the car and back it was one of the more difficult things about the job. At 100+ pounds the Tremec 3550 was far too heavy for me to lift by myself.
I built a trans jack out of 2x6's, some angle iron and a $25 floor jack. If I hadn't done that, I would have needed a helper or to rent a commercial trans jack.
. Anybody have an ballpark of what this will cost me for a rebuild and a new output shaft?
with a tranny jack. It only took me an hour and a half from putting the car on the lift to havin a beer with the tranny on the ground 
I might try to rebuild the tranny later for fun but for now I think upgrading is the right move if i could get some info and opinions on the T-5Z that would be great................
I don't really have the money for a tremec right now too many other things on the go. I see some guys putting decent numbers behind the Z so that's where I might be headed.
