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

NOTE: Attach clutch housing to a suitable holding fixture prior to assembly.

1. Install input shaft seal, if replaced, using tool No. J-26540.

2. Install input shaft outer bearing races, output shaft, and differential into clutch housing, then assemble using a suitable press.




3. Lubricate interlocking pins and install in clutch housing.

4. Using 3rd and 4th shift for alignment, install reverse shift bracket in clutch housing. Install retaining bolts and torque to 22 to 33 ft lbs, ensuring smooth rod operation after installation.

5. Install differential assembly, then the input and output shafts. The 3rd and 4th shift fork and shaft is inserted into the raised collar of the reverse shift lever bracket in clutch housing as an assembly.

6. Install 1st and 2nd shift fork and place shifter shaft in reverse lever bracket. Align hole in fork with shaft and insert roll pin, then assemble reverse lever to shift bracket.

7. Engage reverse shaft and lever while simultaneously installing reverse and 5th gear shifter shaft. Ensure interlock pin is in 5th gear shifter shaft prior to installation.

8. Install reverse idler shaft and gear into clutch housing and insert reverse lever into collar of gear.

9. Using tool No. J33373 measure and determine shim size as follows:




a. Place outer bearing races on input, output, and differential bearings and position shim selection gauges on bearing races.




b. Place 7 spacers provided with tool around perimeter of clutch housing, then install bearing and shim retainer on transaxle case and torque screws to 11 to 16 ft lbs.

c. Place transaxle case over gauges and spacers, install 7 bolts provided with tool and tighten alternately until case is seated, then torque to 10 ft lbs.

d. Rotate gauges to seat bearings, then rotate differential case 3 revolutions in each direction.




e. Compress the three gauges and measure outer sleeve and base pad gap with available shims using the largest shim that can be inserted without binding for proper measurement.

f. When shim selection has been determined, remove case, spacers and gauges.

10. Install selected shims for input, output and differential bearings into their bearing race bores in transaxle case.

11. Using a suitable press, install rear input shaft bearing race, rear output shaft bearing race, and rear differential case bearing race until seated in their bore.

12. Apply a 1/8 inch bead of Loctite No. 14 or equivalent to the clutch housing to transaxle mating surface.

13. Install case magnet, then assemble transaxle case to clutch housing.

14. Install reverse idler shaft bolt in transaxle case and torque to 22 to 33 ft lbs.

15. Install case bolts and torque to 22 to 33 ft lbs, using a diagonal sequence.




16. Install drive axe seals using tool No. J-8092.

17. Assemble output shaft with thrust washer and collar using tool No. J-33374.

18. Install 5th gear on output shaft Install needle bearing, 5th gear, blocker ring, hub and sleeve assembly with fork in groove, and back plate on output shaft. Align shift fork and drive in roll pin.

19. Install detent ball, springs and retaining bolt for reverse, 1st, 2nd, 3rd, 4th and 5th speeds. Torque bolts to 15 to 21 ft lbs.

20. Apply a coat of Loctite 262 or equivalent to threads of input and output shafts and install new retaining nuts and torque to 87 to 101 ft lbs. Stake nuts after torquing.

21. Install gasket and control box assembly on transaxle case and torque retaining bolts 11 to 16 ft lbs.

22. Install gasket and rear cover, ensuring transaxle shifts properly prior to rear cover installation. Torque rear cover bolts to 11 to 16 ft lbs.

23. Install clutch fork assembly, if replaced, and insert clutch shaft bushing into upper hole using tool No. J-28412. Then insert oil seal using tool No. J-28406.

24. Install clutch release bearing.