Dodge Ram Truck 1500-2500-3500. Manual — part 1551

10. Remove shift rail roller bearing from rear housing

(3) with Remover 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

T

degreasing solvent, Gunk

T

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: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out
with crocus cloth.

Bearings: Inspect roller bearings for wear, chips,
cracks, flat-spots or brinnelling. Inspect sealed bear-
ings, and verify bearings roll smoothly.

Gears: Inspect for worn, chipped, or cracked teeth.
Inspect bearing surfaces for wear or flat-spots.

Mainshaft: Inspect for worn splines (1), snap ring
grooves (2) and worn, chipped or cracked teeth (3).
Inspect all bearing surfaces (4) for wear or flat-spots.
Third

and

fourth

gear

(3)

are

serviced

with

mainshaft.

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MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION

DR/DH

Countershaft: Inspect all gears for worn, chipped or
cracked teeth (1). Inspect 3-4 synchronizer assembly
for wear (2). Inspect center support bearing surfaces
(3) for wear or flat-spots. The countershaft with 3-4
synchronizer is serviced as an assembly, except
for bearings.

Synchronizer

components:

Inspect

for

worn,

chipped, or cracked teeth and burned or flaking off
friction material. Synchronizers are serviced as an
assembly.

Input Shaft: Inspect input shaft bearing (1) and bear-
ing surfaces for wear or flat-spots. Inspect input shaft
splines (2) for wear. Inspect snap ring groove (3) for
wear. Inspect fifth gear (4) for worn, chipped, or
cracked teeth.

Shift forks: Inspect shift forks (1) for distortion.
Inspect fork shoes (2) for wear and fit shoes in syn-
chronizer sleeve to ensure parts fit and work smoothly.

DR/DH

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Shift Rails: Inspect shift rails, bushings, and bearing
for wear. Verify main shift rail (1) bearings (2) roll
smoothly.

Clutch Release Bearing Support: Inspect clutch
release bearing support (1) release bearing slide sur-
face (2) for damage.

Housing/Tail housing: Inspect sealing and mating
surfaces are free of burrs and nicks. Inspect alignment
dowels are tight and in good condition. Inspect shift
rail bushings for wear.

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DR/DH

ASSEMBLY

MAINSHAFT

1. Install mainshaft center support bearing (1) on

mainshaft (2).

2. Install sixth gear bearing (1) on mainshaft (2).

DR/DH

MANUAL TRANSMISSION - GETRAG 238 - SERVICE INFORMATION

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