So if i drill & thread the stump using a 6mm tap. what gear should it be in when i tighten the bolt and washer down to prevent it from sliding back into the case?

Ok, i was only thinking that if you put it in 4th gear it'll be sitting as hard to the left as its ever likely too because the drum in 4th pushes the sliding gear on the main shaft to the far side. Therefor that action will keep the drum against the left side. Will just make it easier to drill. Actual 1st gear or 3rd gear would do the same. Bottom line is just keeping it over for easier cleaner drilling. Remember you're drilling under 6mm to tap a 6mm thread. Bit of a guess how deep to drill but probably wouldn't matter if you went right through the end although i never have.

I think i might give it a shot this weekend i guess if it doesn't work out then im tearing it apart anyways. On this bike is it 1 down 3 up? Cause for some reason i can only got 1 down two up trying to shift it

No. All the Enduros are 1 down, 4 up; neutral is between 1st and 2nd.

thats what i was thinking but i can only get it to go one down 3 up. Might need to take it apart anyways could be more issues than i can see

Trans doesn't like to shift if shafts aren't spinning.

Taking it apart is not a bad idea though.