Dodge Getrag 238 Service Manual

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MANUAL TRANS MISSION - GETR AG 238 - S ER VI CE I NF OR MATION

M A N U A L T R A N S M INSF IORNM -AG IEOTNR A G 2 3 8 - S E R V IC E

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 6 9 TABLE O F CO N TEN TS MA N U A L T R A N S MI S S I O N - G E T R A G 238 - S E R V I C E I N F O R MA T I O N TABL E OF CONTENTS

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MANUAL TRANSMISSION - GETRAG 238 SERVICE INFORMATION DIAGNOSIS DIAGNOS IS AND TESTIN TESTING G MANU MA NUAL AL TRA TRANS NSMIS MISSI SION ON - GETRA GETRAG G 238 . . . . . 70 STANDARD PROCEDURE DRAIN AND FI FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 70 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 71 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 SPECIFICATIONS MANU MA NUAL AL TRAN TRANSM SMISS ISSIO ION N - GE GETR TRAG AG 238 . . . . 135 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 137

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MANUAL TR ANS MISSI ON - GETRAG 238 - SERVI CE I NF OR MATI ON

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2 1 - 7 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION DIAGNOSIS AND TESTING MANUAL TRANSMISSION - GETRAG 238 LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or incorrect lubricant level check. Rear transmission leaks will be from the oil seals or transfer case front seal on 4x4. Front transmission leaks will be from the front input shaft retainer seal. Lubricant may drip from the clutch housing after extended operation. If leak is severe, it may contaminate the clutch disc. Lubricant level check can only be made when the vehicle is level and allowing the lubricant to settle for a minute before checking. This will ensure an accurate check and avoid an under or overfill condition.

HARD SHIFTING Hard shi Hard shifti fting ng can be cau caused sed by low lub lubric ricant ant lev level, el, imp improp roper er or con contam tamina inated ted lub lubric ricant ants. s. Thi This s wil willl cau cause se noi noise, se, excessive wear, internal bind, and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. The first indications of component damage is usually hard shifting and noise. Shift component damage, clutch adjustment, worn pressure plate or disc, can increased shift effort. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchronizer rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.

TRANSMISSION NOISE Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds. Severe,, hig Severe highly hly aud audibl ible e tra transm nsmiss ission ion noi noise se is gen genera erally lly the ini initia tiall ind indica icator tor of a lub lubric ricant ant pro proble blem. m. Ins Insuf uffic ficien ient, t, improper or contaminated lubricant will promote rapid wear of gears, synchronizer rings, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.

STANDARD PROCEDURE DRAIN AND FILL 1. Rai Raise se and support support veh vehicle icle.. 2. Rem Remov ove e dr drai ain n pl plug ug (1 (1)) on tr tran ansm smis issi sion on (2 (2)) an and d drain fluid. 3. Insta Installll drain plug and tighten to 50 N·m (37 ft. lbs.). lbs.).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 7 1 4. Rem Remove ove fill plu plug g (1) from side of tra transm nsmiss ission ion (2).

5. Fill Fill tr tran ansm smis issi sion on ev even en wi with th th the e bo bott ttom om of th the e fi fill ll hole. 6. Ins Instal talll fil filll plu plug g and tighten tighten to 50 N·m (37 ft. lbs.). lbs.).

REMOVAL 1. Wit With h veh vehicl icle e in neu neutra tral, l, pos positi ition on veh vehicl icle e on hoi hoist. st. 2. Disco Disconnect nnect battery battery negat negative ive cable. 3. Rem Remov ove e sh shif iftt bo boot ot be beze zell sc scre rews ws an and d sl slid ide e bo boot ot upward on shift lever extension. 4. Remove Remove shift lev lever er ext extens ension ion fro from m the shi shift ft tow tower er and lever assembly. 5. Remo Remove ve 4W 4WD D sh shif iftt bo boot ot if eq equi uipp pped ed an and d re remo move ve floor console. 6. Rem Remove ove skid pla plate, te, if equ equipp ipped. ed. 7. Remove Remove drain drain plu plug g (1) from rear housing housing (2) and drain fluid. 8. Mark Mark pro propel peller ler sha shaft/ ft/sha shafts fts and com compan panion ion fla flange nge yoke/y yok e/yoke okes s for ins instal tallat lation ion ref refere erence nce and rem remove ove propeller shaft/shafts. 9. Dis Disco conn nnec ectt ha harn rnes ess s fr from om cl clip ips s on tr tran ansm smis issi sion on housing. 10. Remo Remove ve transfer case linkage if equipp equipped. ed. 11. Remove Remove transfer case mounting mounting nuts and remove transfer case if equipped. 12. Remove Remove slave cyl cylind inder er (2) mounting mounting nut (1) and remove cylinder.

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2 1 - 7 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 13. Remove Remove starter motor (2), structura structurall dust cover (3) bolts bol ts to clu clutch tch housing, housing, dust shield (1) bol boltt and suspension crossmember (4).

CAUTION CAUTI ON:: Do not rem remove ove str struct uctura urall dus dustt cov cover er from fr om en engi gine ne bl bloc ock. k. If co cove verr is re remo move ved d cl clut utch ch hous ho usiing an and d co cove verr mus ustt be ali lign gned ed wit ith h th the e engine.

14. Remo Remove ve exhaust pipe from the exhaust manifolds. manifolds. 15.. Supp 15 Suppor ortt en engi gine ne wi with th ad adju just stab able le ja jack ck st stan and d an and d wood block. 16. Suppor Supportt and secure secure tra transm nsmiss ission ion (1) to a tra transnsmission jack (2) with safety chains.

17. Remo Remove ve bolts from the rear transmission transmission mount. 18. Remove Remove the rear crossmembe crossmemberr (2) and trans transmismission mount (1). 19.. R 19 Rem emov ove e engine.

bolt bo lts s

atta at tach chin ing g

tran tr ansm smis issi sion on to th the e

20. Move tra transm nsmiss ission ion rea rearwa rward rd unt untilil inp input ut sha shaft ft is clea cl earr of cl clut utch ch di disc sc an and d pr pres essu sure re pl plat ate. e. Th Then en lower low er jac jack k and rem remove ove tra transm nsmiss ission ion fro from m und under er vehicle.

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 7 3 DISASSEMBLY

1. Remo Remove ve shifter socket (1) from main shift rail.

2. R Rem emov ove e ba back ck up la lamp mp sw swit itch ch (1 (1)) bo bolt lt (2 (2)) an and d remove switch.

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2 1 - 7 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 3. Remo Remove ve la larg rge e de dete tent nt pl plug ug,, ne next xt to ba back ck up la lamp mp switch opening with Puller 9583 (1) and Slide Hammer C-3752 (2).

4. Re Remo move ve tw two o smal smalll de dete tent nt pl plug ugs s on to top p of re rear ar hous ho usin ing g wi with th Pu Pulle llerr 88 8870 70 (2 (2)) an and d Sl Slid ide e Ha Hamm mmer er C-3752 (1).

5. Ins Instal talll Wr Wrenc ench h 958 9586 6 (1) on inp input ut shaft (2).

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MANUAL TR ANS MISSI ON - GETRAG 238 - SERVI CE I NFOR MATI ON

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 7 5 6. Remove Remove output output flange flange (1) nut (2) on 4x2 tra transm nsmisission.

7. Remove Remove output flange (1) on 4x2 transmission transmission with Puller 8992 (2) and Button 9618-2.

8. Remove Remove output output shaft nut with Soc Socket ket 9584 (1) on 4x4 transmission (2). 9. Remo Remove ve Wrench 9586 from input shaft. shaft.

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2 1 - 7 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 10. Place Place tra transm nsmiss ission ion on fro front nt hou housin sing g and rem remove ove rearr hou rea housin sing g (2) bol bolts ts (1) (1).. If nec necess essary ary,, rem remove ove the cover plate to access the one rear housing (2) bolt (1) located in the opening.

11. Inst Install all Button 9618-2 (1) into outpu outputt shaft (2).

12.. Sepa 12 Separa rate te re rear ar ho hous usin ing g (1 (1)) fr from om ma mains insha haft ft wi with th Pulle Pu llerr 96 9621 21(2 (2). ). Bo Bolt lt pu pulle llerr to th the e bo bott ttom om of th the e rearr hou rea housin sing, g, the then n tur turn n pul puller ler bol boltt to pus push h mai mainnshaft out of the housing.

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 7 13. Remove Remove reverse shift fork roll pin (1) from reverse shift rail (2).

14.. Slid 14 Slide e re reve vers rse e sh shif iftt ra rail il (1 (1)) do down wn ou outt of th the e sh shif iftt fork (2) and remove reverse shift fork. Then slide shift rail up and out of the front housing.

15. Remove Remove 1-2 shift fork roll pin (1) from shift rail (2). (2). Slide shift rail up out of shift fork and rear housing. Remove 1-2 shift fork.

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2 1 - 7 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 16.. Rota 16 Rotate te ma main in sh shif iftt ra rail il (1 (1)) cl cloc ockw kwis ise e an and d pu pull ll up and out of the front housing.

17. Remove Remove first gear, gear, rever reverse se gear gear,, rever reverse se beari bearing, ng, revers rev erse e gea gearr bea bearin ring g rac race e and rev revers erse e syn synchr chroonizer with Bridge 938 (1), Button 9618-2 (2) and puller Adapters 9628 (3). Position puller Adapters 9628 (3) under first gear.

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 7 9 18. Remo Remove ve first gear bearin bearing g (1) from mainshaft mainshaft (2).

19. Remove Remove first gear synchronizer synchronizer inner friction ring (1) from 1-2 synchronizer hub (2).

20. Remove Remove first gear synchronizer synchronizer outer friction ring (1) from 1-2 synchronizer hub (2).

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2 1 - 8 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 21. Remov Remove e fir first st gea gearr syn synchr chroni onizer zer blo blocke ckerr rin ring g (1) from 1-2 synchronizer hub (2).

22. Rem Remove ove 1-2 syn synchr chroni onizer zer hub (1) snap ring (2) (2)..

23. Remove Remove 1-2 synchronizer synchronizer sleeve (1) from 1-2 synchronizer hub (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 8 1 24. Remo Remove ve 1-2 synchr synchronizer onizer hub (1) detents (2).

25. Remove Remove sec second ond gea gearr and 1-2 syn synchr chroni onizer zer hub with Bridge 938 (1), Button 9618-2 (2) and Adapters 9627 (3).

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2 1 - 8 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 26. Remove Remove interlock plate plate bolts (1) and remove interinterlock plate (2).

27. Remo Remove ve washers (1) from intermediate intermediate plate (2).

28. Remo Remove ve intermediate intermediate plate (1) bolts (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 8 3 29. Remove Remove int interm ermedi ediate ate plate (1) dowels dowels (2) with a suitable tool and remove intermediate plate.

30. Install Install Fixt Fixture ure 9626 (2) on main/ main/count countersha ershaft ft and shift shi ft rai rails. ls. Tu Turn rn fix fixtur ture e (2) with with tra transm nsmiss ission ion (1) over onto the fixture.

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2 1 - 8 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 31. Remove Remove clu clutch tch rel releas ease e bea bearin ring g sup suppor portt bol bolts ts (2) and retainer (1).

32.. Inse 32 Insert rt se seal al Pu Pulle llerr 96 9667 67 th thro roug ugh h on one e in inpu putt sh shaf aftt seal (1) disassembly hole (2).

33. Remove Remove inp input ut sha shaft ft sea seall wit with h Rem Remove overr 966 9667 7 (1) and Slide Hammer C-3752 (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 8 5 34. Rem Remove ove input shaft shaft (1) snap ring (2).

35. Put a hol hole e in the cen center ter of the counter countersha shaft ft plug (2) with a punch (1).

36. Remove Remove cou counte ntersh rshaft aft plu plug g (1) fro from m fro front nt hou housin sing g with Puller 9667 (2) and Slide Hammer C-3752.

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2 1 - 8 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 37. Ins Instal talll Wr Wrenc ench h 958 9586 6 (1) on inpu inputt sha shaft ft (2).

38. Remo Remove ve countershaft countershaft allen bolt (1). 39. Remo Remove ve input shaft wrench.

40.. Remo 40 Remove ve tw two o dete detent nt plu plugs gs fr from om th the e si side de of th the e housin hou sing g wit with h Pul Puller ler 887 8870 0 (1) and Sli Slide de Ham Hammer mer C-3752 (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 8 7 41. Remove Remove 3-4 (2) and 5-6 (1) shift shift for fork k piv pivot ot bolts from both sides of the front housing.

42. Instal Installl Pul Puller ler 962 9621(1 1(1)) wit with h pul puller ler Plu Plug g 962 9621-2 1-2 (2) on fro front nt hou housin sing. g. Tigh ighten ten pul puller ler bol bolts ts eve evenly nly and remo re move ve fr fron ontt ho hous usin ing g fr from om th the e ma main insh shaf aftt an and d countershaft.

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2 1 - 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 43.. Remo 43 Remove ve 55-6 6 sh shif iftt fo fork rk (3 (3)) an and d 33-4 4 sh shif iftt fo fork rk (4 (4). ). Then remove 5-6 shift rail (1) and 3-4 shift rail (2) from Fixture 9626.

44. Remo Remove ve input shaft (1) from mainshaft mainshaft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 8 9 45. Remo Remove ve inpu inputt sha shaft ft bea bearin ring g (1) fro from m mai mainsh nshaft aft (2).

46. Remo Remove ve countershaft countershaft (2) from fixtu fixture re (3).

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2 1 - 9 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R MAINSHAFT

1. Rem Remov ove e fi fift fth h ge gear ar sy sync nchr hron oniz izer er cl clut utch ch bo body dy (1 (1)) from 5-6 synchronizer hub (2).

2. Remove Remove fifth gear synchronizer synchronizer friction friction ring (1) from 5-6 synchronizer hub (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 9 1 3. Remo Remove ve 5-6 synch synchroniz ronizer er sleeve (1) from hub (2).

4. Remo Remove ve 5-6 synchronizer synchronizer detents (1) from hub (2).

5. Rem Remove ove 5-6 syn synchr chroni onizer zer hub (1) snap rin ring g (2) (2)..

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2 1 - 9 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 6. Remo Remove ve 55-6 6 sy sync nchr hron oniz izer er hu hub b (1 (1)) wi with th th thre ree e ja jaw w pulle pu llerr (2 (2)) an and d Bu Butt tton on 96 9618 18-2 -2 (3 (3). ). Po Posi siti tion on ja jaws ws under sixth gear clutch body (4).

7. Remo Remove ve sixth gear (1) from mainshaft mainshaft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 9 3 8. Remo Remove ve sixth gear bearing (1) from mainshaft mainshaft (2).

9. Remove Remove mainshaft center center support bearing (1) from mainshaft (2).

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2 1 - 9 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R COUNTERSHAFT

1. Remov Remove e cou counte ntersh rshaft aft cen center ter sup suppor portt bea bearin ring g (1) from counter shaft (2). NOTE: Count NOTE: Countersha ershaft ft with 3-4 synch synchroniz ronizer er,, is serviced as an assembly except bearings.

CENTER SUPPORT PLATE 1. R Rem emov ove e ce cent nter er su supp ppor ortt (1 (1)) ro rolle llerr be bear aring ing ra race ce retainer (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 9 5 2. Remove Remove mainshaft center support support (1) bearin bearing g race with Remove/Installer 9668 (2) and Handle C4171.

3. Remov Remove e cou counte ntersh rshaft aft cen center ter sup suppor portt (1) bea bearin ring g race rac e wit with h Rem Remove ove/In /Insta stalle llerr 961 9617 7 (2) and Handle Handle C4171.

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2 1 - 9 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R FRONT HOUSING

1. Remove Remove mai mainsh nshaft aft bea bearin ring g ret retain ainer er (1) and cou counntershaft bearing retainers (2). 2. Remove Remove mains mainshaft haft bearing and count countersha ershaft ft bearing with hammer and driver.

REAR HOUSING 1. Remove Remove reverse idler gear gear shaft bolt (1) from housing (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 9 7 2. Remove Remove reverse idler gear shaft (1) from idler gear (2).

3. Remo Remove ve reverse idler gear (1) shaft support (2).

4. Rem Remove ove reverse reverse idle idlerr gea gearr (1) and bea bearin ring g (2) (2)..

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2 1 - 9 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 5. Remo Remove ve mai mainsh nshaft aft bea bearin ring g (1) ret retain ainer er (2) bol bolts ts and remove retainer. 6. Remove Remove bearing bearing fro from m hou housin sing g wit with h a ham hammer mer and driver.

7. Break plastic plastic count countersha ershaft ft roller bearing cage with a screw driver. Then remove cage and roller bearing. 8. Insert Insert Pul Puller ler 958 9585 5 thr throug ough h the cou counte ntersh rshaft aft rol roller ler bear be aring ing sh shel elll (1 (1)) an and d ex expa pand nd th the e to tool ol (2 (2)) to gr grab ab the bottom (3) of the bearing shell (1).

9. Remove Remove counte countersh rshaft aft rol roller ler bea bearin ring g shell shell (1) fro from m the th e re rear ar ho hous using ing wi with th Pu Pulle llerr 95 9585 85 (2 (2)) and and Sl Slid ide e Hammer C-637.

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 9 10. Remove Remove shift rail roller bearing from rear housing (3) with Puller 9609 (1) and Slide Hammer C-637 (2).

CLEANING Clean gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air. Clean shaft bearings with a mild solvent such as MOPAR degreasing solvent, Gunk or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.

INSPECTION NOTE: Min NOTE: Minor or cor corros rosion ion,, nicks, nicks, or pit pittin ting g can be smoo sm ooth thed ed wi with th 40 400 0 gr grit it em emer ery y an and d po poli lish shed ed ou outt with crocus cloth. Bearings: In Insp spec ectt ro rolle llerr be bear arin ings gs fo forr we wear ar,, ch chip ips, s, cracks, crack s, flatflat-spots spots or brinn brinnelling. elling. Inspect sealed bearings, and verify bearings roll smoothly. Gears: Ins Inspec pectt for wor worn, n, chi chippe pped, d, or cra cracke cked d tee teeth. th. Inspect bearing surfaces for wear or flat-spots. Mainshaft: In Insp spec ectt fo forr wo worn rn sp splin lines es (1 (1), ), sn snap ap ri ring ng groove gro oves s (2) and wor worn, n, chi chippe pped d or cra cracke cked d tee teeth th (3) (3).. Inspect all bearing surfaces (4) for wear or flat-spots. Thiird an Th and d fo four urth th ge gear ar (3 (3)) ar are e se serrvi vice ced d wit ith h mainshaft.

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2 1 - 1 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R Countershaft: Inspect all gears for worn, chipped or cracked crack ed teeth (1). Inspe Inspect ct 3-4 synch synchroniz ronizer er assem assembly bly for wear (2). Inspect center support bearing surfaces (3) for wear or flat-spots. The countershaft with 3-4 synchr syn chroni onizer zer is ser servic viced ed as an ass assemb embly ly,, exc except ept for bearings.

Synchroni Synchr onizer zer com compon ponent ents: s: In Insp spec ectt for wor orn, n, chippe chi pped, d, or cra cracke cked d tee teeth th and bur burned ned or fla flakin king g of off f friction frict ion mate material. rial. Syn Synchr chroni onizer zers s are ser servic viced ed as an assembly.

Input Shaft: Inspect input shaft bearing (1) and bearing surfaces for wear or flat-spots. Inspect input shaft splines (2) for wear. Inspect snap ring groove (3) for wear we ar.. In Insp spec ectt fi fift fth h ge gear ar (4 (4)) fo forr wo worn rn,, ch chip ippe ped, d, or cracked teeth.

Shift for Shift forks: ks: In Insp spec ectt sh shif iftt fo fork rks s (1 (1)) fo forr di dist stor orti tion on.. Inspect fork shoes (2) for wear and fit shoes in synchronizer sleeve to ensure parts fit and work smoothly.

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MANUAL TR ANS MIS SI ON - GETRAG 238 - SERVI CE INFOR MATI ON

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 0 Shift Rail Shift Rails: s: Inspe Inspect ct shift rails, bushings, and bearing bearing forr we fo wear ar.. Ver erif ify y ma main in sh shif iftt ra rail il (1 (1)) be bear arin ings gs (2 (2)) ro roll ll smoothly.

Clutch Rel Clutch Releas ease e Bea Bearin ring g Sup Suppor port: t: Ins Inspec pectt clu clutch tch release bearing support (1) release bearing slide surface (2) for damage. Housing/Tail housing: Ins Housing/Tail Inspec pectt sea sealin ling g and mat mating ing surfaces are free of burrs and nicks. Inspect alignment dowels dow els are tig tight ht and in goo good d con condit dition ion.. Ins Inspec pectt shi shift ft rail bushings for wear.

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2 1 - 1 0 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R ASSEMBLY MAINSHAFT

1. Ins Insta tall ll ma main insh shaf aftt ce cent nter er su supp ppor ortt be bear arin ing g (1 (1)) on mainshaft (2).

2. Ins Instal talll six sixth th gea gearr bea bearin ring g (1) on mai mainsh nshaft aft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 0 3 3. Ins Instal talll six sixth th gear (1) on mai mainsh nshaft aft (2).

4. Ins Instal talll six sixth th gear clu clutch tch body (1) on sixth gear (2).

5. Insta Installll sixth gear friction ring (1) on clutch body (2).

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2 1 - 1 0 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 6. Instal Installl 5-6 synchron synchronize izerr hub (1) on mai mainsh nshaft aft with Installer W-262 (2).

7. Ins Instal talll 5-6 synchron synchronize izerr hub (1) sna snap p rin ring g (2) (2)..

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 0 5 8. Ins Instal talll 5-6 synchron synchronize izerr det detent ents s (1) in hub (2).

9. Ins Instal talll 5-6 synchron synchronize izerr sle sleeve eve (1) on hub (2). NOTE: Align grooves in the sleeve with detents in hub.

10. Instal Installl fif fifth th gea gearr syn synchr chroni onizer zer fri fricti ction on rin ring g (1) on 5-6 synchronizer hub (2).

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2 1 - 1 0 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 11. Instal Installl fif fifth th gea gearr syn synchr chroni onizer zer clu clutch tch bod body y (1) on 5-6 synchronizer hub (2).

COUNTERSHAFT 1. Instal Installl cou counte ntersh rshaft aft cen center ter sup suppor portt bea bearin ring g (1) on countershaft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 0 7 CENTER SUPPORT

1. Install Install cent center er support (1) count countersha ershaft ft roller bearing race rac e wit with h Ins Instal taller ler/Re /Remov mover er 961 9617 7 (2) and Han Handle dle C-4171.

2. Instal Installl cen center ter sup suppor portt (1) mai mainsh nshaft aft rol roller ler bearin bearing g race rac e wit with h Ins Instal taller ler/Re /Remov mover er 966 9668 8 (2) and Han Handle dle C-4171.

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2 1 - 1 0 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 3. Instal Installl cen center ter sup suppor portt (1) rac race e ret retain ainer er scr screw ew (2) and tighten to 22 N·m (16 ft. lbs.).

REAR HOUSING 1. Instal Installl mai mainsh nshaft aft bea bearin ring g (1) in rea rearr hou housin sing g wit with h hammer and driver. 2. Ins Insta tall ll ma main insh shaf aftt be bear arin ing g (1 (1)) re reta tain iner er (2 (2). ). Ap Appl ply y Mopar  Lo Lock ck & Se Seal al Ad Adhe hesi sive ve or eq equiv uivale alent nt to retainer bolts and tighten to 10 N·m (88 in. lbs.).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 0 9 3. Install Install shift rail roller bearing bearing (1) with Installer Installer 8475 (2).

4. Instal Installl cou counte ntersh rshaft aft bea bearin ring g wit with h Ins Instal taller ler 962 9624 4 (1) and Handle C-4171 (2).

5. Ins Instal talll idle idlerr gea gearr (1) in rea rearr hou housin sing g (2) (2)..

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2 1 - 1 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 6. Ins Instal talll idle idlerr gea gearr bea bearin ring g (1) in idle idlerr gea gearr (2) (2)..

7. Ins Instal talll idle idlerr gea gearr (1) shaft support support (2).

8. Ins Instal talll idle idlerr gea gearr (2) shaft shaft (1) (1)..

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 9. Instal Installl sha shaft ft bolt and alig align n idle idlerr gea gearr sha shaft ft (1) wit with h shaft bolt (2).

10. Apply Mopar  Lock & Seal Adhesive or equivalent to idler shaft bolt. Tighten bolt (1) in housing (2) to 25 N·m (18 ft. lbs.).

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2 1 - 1 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R FRONT HOUSING

1. Install Install mains mainshaft haft and count countersha ershaft ft bearings in front housing with hammer and driver. 2. Instal Installl mai mainsh nshaft aft bea bearin ring g ret retain ainer er (1) and cou counte nterrshaft sha ft bea bearin ring g ret retain ainers ers (2) (2).. App Apply ly Mop Mopar ar  Lock & Seall Adh Sea Adhesi esive ve or equ equiva ivalen lentt to ret retain ainer er bol bolts ts and tighten to 10 N·m (88 in. lbs.).

3. Instal Installl mai mainsh nshaft aft (1) and cou counte ntersh rshaft aft (2) in bui build ld Fixture 9626 (3).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 4. Insta Installll input shaft bearing (1) on mains mainshaft haft (2).

5. Ins Instal talll inp input ut sha shaft ft (1) on mai mainsh nshaft aft (2).

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2 1 - 1 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 6. Instal Installl 5-6 shift shift rail (1) and 3-4 shift rail (2) in bui build ld Fixture 9626. Then install 5-6 shift fork (3) and 3-4 shift fork (4)

WARNING: Use tongs when handling heated component pon ents. s. Fai Failur lure e to fol follow low the these se ins instru tructi ctions ons wi will ll result in personal injury. CAUTIO CAUT ION: N: A be bear arin ing g he heat ater er (3 (3)) is us used ed to he heat at Plug 9625 (1) and Plug 9619-1 (2). Use only a bearing in g he heat ater er/h /hot ot pl plat ate e an and d fo foll llow ow ma manu nufa fact ctur ure’ e’s s instru ins tructi ctions ons.. Hea Heatt com compon ponent ents s to 100 - 177 Cel Cel-sius (212° Min. - 350° Max Fahrenheit). Never use an ope open n fla flame me to hea heatt com compon ponent ents. s. Nev Never er lea leave ve components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used us ed.. Fa Fail ilur ure e to fo foll llow ow th thes ese e in inst stru ruct ctio ions ns wi will ll result in component damage. 7. Heat Heat Plug 9625 (1) and Plug 9619-1 9619-1 (2) to a max max-imum of 177 Celsius (350° Fahrenheit) with bearing heater (3).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 5 8. With tongs place heated Plug 9625 in countershaft countershaft bear be aring ing an and d he heat ated ed Pl Plug ug 96 9619 19-1 -1 in into to ma main insh shaf aftt bear be arin ing. g. Al Allo low w pl plug ugs s to he heat at be bear arin ings gs fo forr tw two o minutes.

9. Remo Remove ve Pl Plug ug 96 9625 25 an and d Pl Plug ug 96 9619 19 wi with th we weld lding ing gloves glo ves or ton tongs, gs, then ins instal talll fro front nt hou housin sing g (1) on mainshaft and countershaft in fixture (2).

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2 1 - 1 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 10. Apply Mopar  Lock & Seal Adhesive or equivalent to shift fork pivot bolts. Install 5-6 (1) and 3-4 (2) shif sh iftt fo fork rk piv pivot ot bo bolt lts, s, in bo both th si side des s of th the e fr fron ontt housing and tighten to 35 N·m (26 ft. lbs.). NOTE: Verify shift fork pivot holes are aligned with pivot bolt holes before installing bolts.

11. Install Install two detents (1) in the side of the front housing (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 7 FINAL ASSEMBL ASSEMBLY Y

1. Turn Turn front housing (1) with fixture fixture (2) over onto the front housing and remove fixture.

2. Insta Installll intermediate intermediate plate (1) and two dowel dowels s (2).

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2 1 - 1 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 3. Install Install intermediate intermediate plate (1) bolts (2) and tighten to 22 N·m (16 ft. lbs.).

4. Insta Installll interlock plate washers washers (1) on suppo support rt (2).

5. Instal Installl int interl erlock ock plate (2) and tig tighte hten n bol bolts ts (1) to 10 N·m (88 in. lbs.).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 9 6. Insta Installll second gear bearing (1) on mains mainshaft haft (2).

7. Ins Instal talll sec second ond gear (1) on mai mainsh nshaft aft (2).

8. Install Install second gear inner friction friction ring (1) on second gear (2).

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2 1 - 1 2 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 9. Install Install second gear outer friction friction ring (1) on secon second d gear (2).

10.. Inst 10 Instal alll se seco cond nd ge gear ar blo block cker er ri ring ng (1 (1)) on se seco cond nd gear (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 2 11. Align 1-2 synchronizer synchronizer hub (1) with blocker blocker ring on mainshaft and install hub with Installer D-389 (2).

NOTE: If 1-2 syn NOTE: synchr chroni onizer zer hub is ins instal talled led inc incororrectly the snap ring groove will not be visible.

12. Ins Instal talll 1-2 synchron synchronize izerr hub (1) sna snap p rin ring g (2) (2)..

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2 1 - 1 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 13. Insta Installll 1-2 synch synchroniz ronizer er hub (1) detents (2).

14. Insta Installll 1-2 synchronizer synchronizer sleeve (2) on 1-2 hub (1). NOTE: Align grooves in the sleeve with detents in hub.

15. Ins Instal talll fir first st gear blo blocke ckerr rin ring g (1) on 1-2 hub (2) (2)..

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 2 3 16. Instal Installl fir first st gear out outer er friction friction ring (1) on 1-2 hub (2).

17. Instal Installl fir first st gear inn inner er friction friction ring (1) on 1-2 hub (2).

18. Insta Installll first gear bearing (1) on mains mainshaft haft (2).

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2 1 - 1 2 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 19. Ins Instal talll fir first st gea gearr (1) on mai mainsh nshaft aft (2).

WAR ARNI NING NG:: Us Use e we weld ldin ing g gl glov oves es or to tong ngs s wh when en hand ha ndli ling ng he heat ated ed co comp mpon onen ents ts.. Fa Fail ilur ure e to fo foll llow ow these instructions will result in personal injury. CAUTION: A bearing heater is used to heat reverse bear be arin ing g ra race ce (1 (1). ). Us Use e on only ly a be bear arin ing g he heat ater er/h /hot ot plate and follow manufacturer’s instructions. Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat compon com ponent ents. s. Nev Never er lea leave ve com compon ponent ents s on hea heater ter for an ext extend ended ed amo amount unt of tim time. e. If componen componentt is discolored after heating, the component has been overhe ove rheate ated d and mus mustt not be use used. d. Fai Failur lure e to fol fol-low the these se ins instru tructi ctions ons wil willl res result ult in com compon ponent ent damage. 20. Heat reverse reverse bearing race (1) with beari bearing ng heater (2) to a maximum of 177 Celsius (350° Fahrenheit). 21. With welding welding gloves or tongs install install reverse bearing race (1) on mainshaft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 2 5 22. Instal Installl rev revers erse e gea gearr bea bearin ring g (1) on bea bearin ring g rac race e (2).

23. Insta Installll reverse gear (1) on mains mainshaft haft (2).

24.. Inst 24 Instal alll re reve vers rse e ge gear ar fr fric icti tion on/b /bloc locke kerr ri ring ng (1 (1)) on reverse gear (2).

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2 1 - 1 2 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 25. Install Install reverse synchronizer synchronizer detents detents (1) in rever reverse se hub (2).

26. Install Install reverse synchronizer synchronizer sleeve (1) on rever reverse se hub (2). NOTE: Align grooves in the sleeve with detents in hub.

27.. Inst 27 Instal alll re reve vers rse e ge gear ar sy sync nchr hron oniz izer er hu hub b (1 (1)) wi with th Installer D-389 (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 2 7 28. Install Install main shift rail (1) bearings bearings (2) on main shift rail.

29. Instal Installl mai main n shi shift ft rai raill (1) through through rai raill sup suppor portt (2) and hou housin sing, g, the then n rot rotate ate cou counte ntercl rclock ockwis wise e int into o place.

30. Instal Installl 1-2 shift fork then, install install 1-2 shift rail (2) into shift fork and housing. Install shift fork roll pin (1).

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2 1 - 1 2 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 31. Install Install reverse shift rail (1) into the housing. Then Then instal ins talll rev revers erse e shi shift ft for fork k (2) and pul pulll shi shift ft rai raill (1) up into the shift fork.

32. Ins Instal talll rev revers erse e shi shift ft fork rol rolll pin (1).

WARNING: Use tongs when handling heated component pon ents. s. Fai Failur lure e to fol follow low the these se ins instru tructi ctions ons wi will ll result in personal injury. CAUTIO CAUT ION: N: A be bear arin ing g he heat ater er (2 (2)) is us used ed to he heat at Plug Pl ug 96 9619 19-2 -2 (1 (1). ). Us Use e on only ly a be bear arin ing g he heat ater er/h /hot ot plate and follow manufacturer’s instructions. Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat compon com ponent ents. s. Nev Never er lea leave ve com compon ponent ents s on hea heater ter for an ext extend ended ed amo amount unt of tim time. e. If componen componentt is discolored after heating, the component has been overhe ove rheate ated d and mus mustt not be use used. d. Fai Failur lure e to fol fol-low the these se ins instru tructi ctions ons wil willl res result ult in com compon ponent ent damage. 33. Heat Heat Plu Plug g 961 9619-2 9-2 (1) with bearing bearing heater heater (2) to a maximum of 177 Celsius (350° Fahrenheit).

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21 - 129

D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 2 9 34.. With to 34 tong ngs s pl plac ace e Plug Plug 96 9619 19-2 -2 in re rear ar ho hous usin ing g mainshaft bearing (2). Allow plug to heat bearing for two minutes.

35.. Appl 35 Apply y a be bead ad of Mo Mopa par r  Gasket Maker or equivalent to the front housing sealing surface. 36. Remove Remove plug and ins instal talll rea rearr hou housin sing g (1) on fro front nt housing (2). 37. Instal Installl hou housin sing g bolt bolts s and tighten tighten to 22 N·m (16 ft. lbs.).

38. Instal Installl out output put shaft seal in rea rearr hou housin sing g (1) with Installer 9629 (2).

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2 1 - 1 3 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 39.. Ins 39 Insta tall ll 4x 4x4 4 tr tran ansm smis issi sion on ou outp tput ut sh shaf aftt nu nutt wi with th Socket 9584 and tighten to 200 N·m (147 ft. lbs.). Then loosen nut and tighten to 170 N·m (125 ft. lbs.).

40.. Driv 40 Drive e ou outp tput ut sh shaf aftt fl flan ange ge on onto to th the e ou outp tput ut sh shaf aftt with Installer D-389. 41. Ins Instal talll 4x2 tra transm nsmiss ission ion out output put sha shaft ft fla flange nge (1) and tighten bolt (2) to 200 N·m (147 ft. lbs.). Then loosen bolt and tighten to 170 N·m (125 ft. lbs.). Remove Wrench 9586 from input shaft.

42.. Inst 42 Instal alll tw two o de dete tent nt pl plug ugs s in th the e to top p of th the e re rear ar housing. 43. Instal Installl lar large ge det detent ent plunger plunger (1) and spr spring ing (2) in the side of the rear housing.

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 44. Instal Installl lar large ge detent detent plug (1) in the side of the rear rear housing (2).

45. Install Install back up lamp switch switch (1) and tight tighten en bolt (2) to 10 N· N·m m (8 (88 8 in. lb lbs. s.). ). Th Then en lay tr tran ansm smis issi sion on down on bench.

46. Ins Instal talll inp input ut shaft (1) snap rin ring g (2) (2)..

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2 1 - 1 3 2 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R 47.. In 47 Inst stal alll in inpu putt sh shaf aftt se seal al in fr fron ontt ho hous usin ing g wi with th Installer 9620 (1) and Tube C-3717 (2).

48.. Ins 48 Insta tall ll cl clut utch ch be bear arin ing g re rele leas ase e su supp ppor ortt (1 (1)) an and d tighten bolts (2) to 10 N·m (88 in. lbs.).

49. Ins Instal talll Wr Wrenc ench h 958 9586 6 (1) on inpu inputt sha shaft ft (2).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 50.. In 50 Inst stal alll co coun unte ters rsha haft ft bo bolt lt (1) (1) in fr fron ontt ho hous usin ing. g. Tighten bolt (1) to 90 N·m (66 ft. lbs.).

51. Instal Installl cou counte ntersh rshaft aft plug in fro front nt hou housin sing g (1) wit with h Installer 9622 (2) and Handle C-4171.

52. Instal Installl the cover plate for the second second shi shift ft tow tower er location, if necessary. 53. Apply Apply Mopar Mopar  Lock & Seal or equivalent to shifter socket threads and install shifter socket (1).

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2 1 - 1 3 4 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R INSTALLATION

1. Clean transmission transmission front housing mounting mounting surfa surface. ce. 2. Apply light coat of Mopar high temperature temperature bearing bearing grease or equivalent to contact surfaces of following components: release fork (1) ball stud (2) release bearing slide surface (3) input shaft splines (4) release bearing bore (5) propeller shaft slip yoke. • • • • •

3. Suppo Support rt and secure transmission transmission to jack. 4. Raise and align transmission transmission input shaft with clutch disc, then slide transmission into place. 5. Verify front housing housing is fully seated. seated. Install transmistransmission bolts without washers (1) and tighten bolts into the engine to 41 N·m (30 ft. lbs.). Tighten the bolts with wit h was washer hers s (2) into the transmis transmissio sion n to 68 N· N·m m (50 ft. lbs.). 6. Inst Instal alll re rear ar cr cros ossm smem embe berr (1 (1)) an and d ti tigh ghte ten n nu nuts ts to 102 N·m (75 ft. lbs.). 7. Install Install transmission transmission rear mount (2) bolts and tighten to 68 N·m (50 ft. lbs.).

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 5 8. Instal Installl fro front nt dust shi shield eld (1) tig tighte hten n bol boltt to 4.5 N· N·m m (40 in. lbs.). 9. Install Install structural structural cover (3) to transmission transmission bolts and tighten to 54 N·m (40 ft. lbs.). 10. Insta Installll starter motor motor (2). 11. Instal Installl sus suspen pensio sion n cro crossm ssmemb ember er (4) and tig tighte hten n nuts to 102 N·m (75 ft. lbs.).

12. Connect Connect transmission transmission harnesses harnesses to clips on case and connect switches. 13. Instal Installl sla slave ve cyl cylind inder er (2) and tig tighte hten n cyl cylind inder er nut nuts s (1) to 23 N·m (200 in. lbs.). 14. Instal Installl tra transf nsfer er cas case e and tra transf nsfer er cas case e lin linkag kage e if equipped. 15. Remo Remove ve transmission transmission jack. 16. Install Install prope propeller ller shaft shaft/shaf /shafts ts with reference reference marks aligned. 17. Insta Installll exhaust on the exhaust manifolds. manifolds. 18. Fill transmission transmission with lubricant. lubricant. Correct fill level is to bottom edge of fill plug hole.

SPECIFICATIONS MANUAL TRANSMISSION - GETRAG 238 TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Drain Plug

50

37

-

Fill Plug

50

37

-

Shift Tower Bolts

10

-

88

Back Up Lamp Switch Bolt

10

-

88

4x2 Output Flange Bolt

200 then loosen and tighten to 170


-

4x4 Output Shaft Nut



-

Housing Bolts

22

16

-

Interlock Plate Bolts

10

-

88

Intermediate Support Bolts

22

16

-

Intermediate Support Race Retainer Bolt

22

16

-

Countershaft Bolt

90

66

-

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2 1 - 1 3 6 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Reverse Rever se Idler Gear Shaf Shaftt Bolt

25

18

-

Mainshaft, Countershaft Bearing Retainer Bolts

10

-

88

Input Shaft Retainer Bolts

10

-

88

Shift Fork Pivot Bolts

35

26

-

Support Braket to Trans Bolts

54

40

-

GEAR SPECIFICATIONS GEAR

RATIO

FIRST

4.23

SECOND

2.53

THIRD

1.67

FOURTH

1.23

FIFTH

1.00

SIXTH

0.79

REVERSE

3.84

DR

MANUAL TRANS MISSI ON - GETRAG 238 - SERVI CE INFOR MATI ON

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 7 SPECIAL TOOLS

INSTALLER W-262 INSTALLER C-3717

INSTALLER 8475

SLIDE HAMMER C-3752

PULLER 8870

SLIDE HAMMER C-637

PULLER 8992

INSTALLER D-389

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2 1 - 1 3 8 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R BRIDGE 938

WRENCH 9586

PULLER 9583

PULLER 9609

SOCKET 9584

REMOVER/INSTALLER 9617

PULLER 9585

PULLER 9618

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MANUAL TRANS MISSI ON - GETRAG 238 - SERVI CE INFOR MATI ON

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D R M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N 2 1 - 1 3 9 BUTTON 9618-2

INSTALLER 9622

HEAT PLUG 9619-1 & 9619-2

INSTALLER 9624

INSTALLER 9620

HEAT PLUG 9625

PULLER 9621

FIXTURE 9626

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2 1 - 1 4 0 M A N U A L T R A N S M IS IO N - G E T R A G 2 3 8 - S E R V IC E IN F O R M A T IO N D R PULLER ADAPTER 9627

PULLER ADAPTER 9628

INSTALLER 9629

REMOVER 9667

REMOVER/INSTALLER 9668

Dodge Getrag 238 Service Manual

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