Dodge Getrag 238 Service Manual
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MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION 21 - 69
MANUAL TRANSMISSION - GETRAG 238 - SERVICE
INFORMATION
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - GETRAG 238 -
SERVICE INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - GETRAG 238 . . . . . 70
STANDARD PROCEDURE
DRAIN AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
SPECIFICATIONS
MANUAL TRANSMISSION - GETRAG 238 . . . . 135
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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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 shifting can be caused by low lubricant level, improper or contaminated lubricants. This will cause noise,
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, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient,
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. Raise and support vehicle.
2. Remove drain plug (1) on transmission (2) and
drain fluid.
3. Install drain plug and tighten to 50 N·m (37 ft. lbs.).
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4. Remove fill plug (1) from side of transmission (2).
5. Fill transmission even with the bottom of the fill
hole.
6. Install fill plug and tighten to 50 N·m (37 ft. lbs.).
MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION 21 - 71
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Disconnect battery negative cable.
3. Remove shift boot bezel screws and slide boot
upward on shift lever extension.
4. Remove shift lever extension from the shift tower
and lever assembly.
5. Remove 4WD shift boot if equipped and remove
floor console.
6. Remove skid plate, if equipped.
7. Remove drain plug (1) from rear housing (2) and
drain fluid.
8. Mark propeller shaft/shafts and companion flange
yoke/yokes for installation reference and remove
propeller shaft/shafts.
9. Disconnect harness from clips on transmission
housing.
10. Remove transfer case linkage if equipped.
11. Remove transfer case mounting nuts and remove
transfer case if equipped.
12. Remove slave cylinder (2) mounting nut (1) and
remove cylinder.
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13. Remove starter motor (2), structural dust cover (3)
bolts to clutch housing, dust shield (1) bolt and
suspension crossmember (4).
CAUTION: Do not remove structural dust cover
from engine block. If cover is removed clutch
housing and cover must be aligned with the
engine.
14. Remove exhaust pipe from the exhaust manifolds.
15. Support engine with adjustable jack stand and
wood block.
16. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.
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17. Remove bolts from the rear transmission mount.
18. Remove the rear crossmember (2) and transmis-
sion mount (1).
19. Remove bolts attaching transmission to the
engine.
20. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.
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DISASSEMBLY
1. Remove shifter socket (1) from main shift rail.
2. Remove back up lamp switch (1) bolt (2) and
remove switch.
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3. Remove large detent plug, next to back up lamp
switch opening with Puller 9583 (1) and Slide Hammer C-3752 (2).
4. Remove two small detent plugs on top of rear
housing with Puller 8870 (2) and Slide Hammer
C-3752 (1).
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5. Install Wrench 9586 (1) on input shaft (2).
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6. Remove output flange (1) nut (2) on 4x2 transmission.
7. Remove output flange (1) on 4x2 transmission with
Puller 8992 (2) and Button 9618-2.
MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION 21 - 75
8. Remove output shaft nut with Socket 9584 (1) on
4x4 transmission (2).
9. Remove Wrench 9586 from input shaft.
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10. Place transmission on front housing and remove
rear housing (2) bolts (1). If necessary, remove
the cover plate to access the one rear housing (2)
bolt (1) located in the opening.
11. Install Button 9618-2 (1) into output shaft (2).
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12. Separate rear housing (1) from mainshaft with
Puller 9621(2). Bolt puller to the bottom of the
rear housing, then turn puller bolt to push mainshaft out of the housing.
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13. Remove reverse shift fork roll pin (1) from reverse
shift rail (2).
14. Slide reverse shift rail (1) down out of the shift
fork (2) and remove reverse shift fork. Then slide
shift rail up and out of the front housing.
MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION 21 - 77
15. Remove 1-2 shift fork roll pin (1) from shift rail (2).
Slide shift rail up out of shift fork and rear housing. Remove 1-2 shift fork.
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16. Rotate main shift rail (1) clockwise and pull up
and out of the front housing.
17. Remove first gear, reverse gear, reverse bearing,
reverse gear bearing race and reverse synchronizer 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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18. Remove first gear bearing (1) from mainshaft (2).
19. Remove first gear synchronizer inner friction ring
(1) from 1-2 synchronizer hub (2).
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20. Remove first gear synchronizer outer friction ring
(1) from 1-2 synchronizer hub (2).
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21. Remove first gear synchronizer blocker ring (1)
from 1-2 synchronizer hub (2).
22. Remove 1-2 synchronizer hub (1) snap ring (2).
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23. Remove 1-2 synchronizer sleeve (1) from 1-2 syn-
chronizer hub (2).
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24. Remove 1-2 synchronizer hub (1) detents (2).
25. Remove second gear and 1-2 synchronizer hub
with Bridge 938 (1), Button 9618-2 (2) and Adapters 9627 (3).
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26. Remove interlock plate bolts (1) and remove inter-
lock plate (2).
27. Remove washers (1) from intermediate plate (2).
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28. Remove intermediate plate (1) bolts (2).
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29. Remove intermediate plate (1) dowels (2) with a
suitable tool and remove intermediate plate.
30. Install Fixture 9626 (2) on main/countershaft and
shift rails. Turn fixture (2) with transmission (1)
over onto the fixture.
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31. Remove clutch release bearing support bolts (2)
and retainer (1).
32. Insert seal Puller 9667 through one input shaft
seal (1) disassembly hole (2).
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33. Remove input shaft seal with Remover 9667 (1)
and Slide Hammer C-3752 (2).
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34. Remove input shaft (1) snap ring (2).
35. Put a hole in the center of the countershaft plug
(2) with a punch (1).
MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION 21 - 85
36. Remove countershaft plug (1) from front housing
with Puller 9667 (2) and Slide Hammer C-3752.
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37. Install Wrench 9586 (1) on input shaft (2).
38. Remove countershaft allen bolt (1).
39. Remove input shaft wrench.
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40. Remove two detent plugs from the side of the
housing with Puller 8870 (1) and Slide Hammer
C-3752 (2).
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41. Remove 3-4 (2) and 5-6 (1) shift fork pivot bolts
from both sides of the front housing.
42. Install Puller 9621(1) with puller Plug 9621-2 (2)
on front housing. Tighten puller bolts evenly and
remove front housing from the mainshaft and
countershaft.
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43. Remove 5-6 shift fork (3) and 3-4 shift fork (4).
Then remove 5-6 shift rail (1) and 3-4 shift rail (2)
from Fixture 9626.
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44. Remove input shaft (1) from mainshaft (2).
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45. Remove input shaft bearing (1) from mainshaft
(2).
46. Remove countershaft (2) from fixture (3).
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MAINSHAFT
1. Remove fifth gear synchronizer clutch body (1)
from 5-6 synchronizer hub (2).
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2. Remove fifth gear synchronizer friction ring (1) from
5-6 synchronizer hub (2).
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