GM 5SPD (Isuzu 76mm) Passenger Exc.Nova

1. Remove clutch release bearing and attach case to suitable holding fixture. Remove rear cover.

2. Remove control box assembly, then using a screwdriver, shift transaxle into gear. Remove retaining nuts for 5th speed drive gear and driven gear from the input and output shafts. Shift transaxle back to neutral and align shift rail detents.







3. Remove 1st, 2nd, 3rd, 4th, reverse and 5th detent spring retaining bolts, detent springs, detent balls and detents.

4. Place 5th speed synchronizer in neutral position. Drive out roll pin from shift fork and remove 5th gear synchronizer hub, sleeve, bearing, gear and shift fork as an assembly. Remove 5th speed gear from input shaft.

5. Remove bearing retainer and shims from input and output shafts.

6. Remove reverse idler shaft retaining bolt and shaft from transaxle case, then the collar and thrust washer from output shaft, using a suitable puller.

7. Separate transaxle case from clutch housing and remove reverse idler gear and shaft.

8. Raise 5th gear to align detents and remove 5th and reverse gear shafts simultaneously.

9. Remove 1-2 shift fork roll pin, slide shaft upward, and lift fork and shaft from case.

10. Remove input shaft, output shaft and 3-4 fork with shaft as an assembly, then the differential assembly.




11. Remove reverse shift bracket and three interlock pins.




12. Remove rear bearing outer race using tool No. J-24256-A from case. Use tool No. J-33370 to remove output shaft race. Tool No. J-8092 can be used as a common driver for both applications.

13. Remove outer races for input shaft, output shaft and differential side bearings using tool No. J-26941 and a suitable slide hammer.

14. Remove input shaft seal, clutch shaft seal and fork assembly only if replacement is necessary.