Operation CHARM: Car repair manuals for everyone.

Disassembly

MANUAL TRANSMISSION-GETRAG 238

DISASSEMBLY





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





2. Remove back up lamp switch (1) bolt (2) and remove switch.





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).





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





6. Remove output flange (1) nut (2) on U2 transmission.





7. Remove output flange (1) on U2 transmission with Puller 8992 (2) and Button 9618-2.





8. Remove output shaft nut with Socket 9584 (1) on U4 transmission (2).
9. Remove Wrench 9586 from input shaft.





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).





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.





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.





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.





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.





18. Remove first gear bearing (1) from mainshaft (2).





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





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





21. Remove first gear synchronizer blocker ring (1) from 1-2 synchronizer hub (2).





22. Remove 1-2 synchronizer hub (1) snap ring (2).





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





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).





26. Remove interlock plate bolts (1) and remove interlock plate (2).





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





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





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.





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).





33. Remove input shaft seal with Remover 9667 (1) and Slide Hammer C-3752 (2).





34. Remove input shaft snap ring.





35. Put a hole in the center of the countershaft plug (2) with a punch (1).





36. Remove countershaft plug (1) from front housing with Puller 9667 (2) and Slide Hammer C-3752.





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





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





40. Remove two detent plugs from the side of the housing with Puller 8870 (1) and Slide Hammer C-3752 (2).





41. Remove 3-4 (2) and 5-6 (1) shift fork pivot bolts from both sides of the front housing.





42. Install Puller 9621(l) with puller Plug 9621-2 (2) on front housing. Tighten puller bolts evenly and remove front housing from the mainshaft and countershaft.





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.





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





45. Remove input shaft bearing (1) from mainshaft (2).





46. Remove countershaft (2) from fixture (3).

MAINSHAFT





1. Remove fifth gear synchronizer clutch body (1) from 5-6 synchronizer hub (2).





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





3. Remove 5-6 synchronizer sleeve (1) from hub (2).





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





5. Remove 5-6 synchronizer hub (1) snap ring (2).





6. Remove 5-6 synchronizer hub (1) with three jaw puller (2) and Button 9618-2 (3). Position jaws under sixth gear clutch body (4).





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





8. Remove sixth gear bearing (1) from mainshaft (2).





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

COUNTERSHAFT





1. Remove countershaft center support bearing (1) from counter shaft (2).

NOTE: Countershaft with 3-4 synchronizer, is serviced as an assembly except bearings.

CENTER SUPPORT PLATE





1. Remove center support (1) roller bearing race retainer (2).





2. Remove mainshaft center support (1) bearing race with Remove/Installer 9668 (2) and Handle C4171.





3. Remove countershaft center support (1) bearing race with Remove/Installer 9617 (2) and Handle C4171.

FRONT HOUSING





1. Remove mainshaft bearing retainer (1) and countershaft bearing retainers (2).
2. Remove mainshaft bearing and countershaft bearing with hammer and driver.

REAR HOUSING





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





2. Remove reverse idler gear shaft (1) from idler gear (2).





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





4. Remove reverse idler gear (1) and bearing (2).





5. Remove mainshaft bearing (1) retainer (2) bolts and remove retainer.
6. Remove bearing from housing with a hammer and driver.





7. Break plastic countershaft roller bearing cage with a screw driver. Then remove cage and roller bearing.
8. Insert Puller 9585 through the countershaft roller bearing shell (1) and expand the tool (2) to grab the bottom (3) of the bearing shell (1).





9. Remove countershaft roller bearing shell (1) from the rear housing with Puller 9585 (2) and Slide Hammer C-637.





10. Remove shift rail roller bearing from rear housing (3) with Puller 9609 (1) and Slide Hammer C-637 (2).