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 is usually 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 are also causes of 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 bear-
ings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.

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REMOVAL

1. Remove drain plug (1) from rear housing (2) and

drain fluid.

2. With vehicle in neutral, position vehicle on hoist.

3. Disconnect battery negative cable.

4. Remove shift boot bezel screws and slide boot

upward on shift lever extension.

5. Remove shift lever extension from the shift tower

and lever assembly.

6. Remove skid plate, if equipped.

7. Drain lubricant if transmission will be disassembled

for service.

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.

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 enigne block. If cover is removed clutch
housing and cover must be aligned with the
engine.

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MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION

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14. Remove exhaust pipe from the exhaust manifolds.

15. Support engine with adjustable jack stand and

wood block.

16. Support and secure transmission to a transmis-

sion jack with safety chains.

17. Remove bolts from the rear transmission mount.

18. Remove the rear crossmember (2) and transmis-

sion mount (1).

19. Remove

bolts

attaching

transmission

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.

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 Remover 9583 (1) and Slide
Hammer C-3752 (2).

4. Remove two small detent plugs on top of rear

housing with Remover 8870 (2) and Slide Hammer
C-3752 (1).

5. Install Wrench 9586 (1) on input shaft (2).

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MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION

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