Top of pageAbstract The recently described method for producing recombinant adeno-associated virus (rAAV) type 2 in insect cells facilitates scale-up by using suspension cell cultures and baculovirus expression vectors (Hum Gene Ther 13:1935-1943, 2002). AAV5 is one of the most divergent dependovirus characterized and has been shown to utilize different receptors than AAV2 for example, and has demonstrated different tissue tropism from other serotype rAAVs. In addition to vectors derived from serotype 2, other serotypes constitute a vector set from which an optimal one can be selected for specific applications. Thus, we established a method to generate rAAV5 in insect cells. The current process requires triple infection with recombinant baculoviruses that provide the following: 1. AAV structural proteins that form the virus capsid (VP 1, 2, 3); 2. two of the AAV non-structural proteins for replication and encapsidation (Rep 78 and Rep 52); and 3. the AAV vector DNA which contain the gene of interest flanked by the AAV origins of replication (ITRs). Compared to other rAAV serotypes produced in insect cells, the rAAV5 yield per cell was substantially lower and we tested some modifications of the system. The initial Rep baculovirus drove type 5 Rep72 expression with a truncated promoter for the immediate-early 1 gene of Orgyia pseudotsugata nuclear polyhedrosis virus. The titers of the Rep baculovirus were relatively lower than others. We constructed Rep baculoviruses with a series of truncated p10 promoters for Rep78 and selected one that could produce rAAV5 at a high titer and propagate well. Rep52 or small Rep protein packages AAV genome into preformed empty capsids. We examined Rep52 of other serotypes, 1, 2, 3, 4 for generation of rAAV5 particles. The titer of rAAV5-GFP produced with type 1, 2, 3, or 4 small Rep was 56,000|[plusmn]|3,200, 41,000|[plusmn]|18,900, 42,000|[plusmn]|7,300, or 39,000|[plusmn]|3,500 particles per Sf9 cell while rAAV5-GFP produced by authentic Rep52 was 13,500|[plusmn]|3,200. The rAAV5-GFP produced with either serotype small Rep has an equal ratio of nucleic acid to capsid protein assessed by real-time PCR quantification and silver staining of purified rAAV5 particles. Also, rAAV5-GFP produced with either combination of large and small Rep proteins, transduced the simian Cos cell line with similar efficiency. The analysis by cesium density gradient of insect-cell lysates indicated that approximately 50% of all capsids contained the vector genome. These results indicate that heteroserotypic small Rep polypeptide is able to substitute for AAV5 small Rep and package AAV vector genome with type 5 in Sf9 cells and the new Rep baculovirus expressing type 5 Rep78 under the control of a truncated p10 promoter and type 1 Rep52 will contribute to the development of more efficient production of rAAV5 in insect cells.