2006 DODGE RAM SRT-10 manual transmission

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MANUAL TRANSMISSION - GETRAG 238 -
SERVICE INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - GETRAG 238 . . . . . 71
STANDARD PROCEDURE
DRAIN AND FILL ............................ 71
REMOVAL .................................... 72
DISASSEMBLY ............................... 74CLEANING .................................. 100
INSPECTION . . .............................. 100
ASSEMBLY .................................. 103
INSTALLATION .............................. 135
SPECIFICATIONS
MANUAL TRANSMISSION - GETRAG 238 . . . . 136
SPECIAL TOOLS ............................ 138

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 leakswill be from the oil seals or transfer case front seal on 4x4.
Front transmission leakswill be from the front input shaft retainer seal. Lubricant may drip from theclutchhousing
after extended operation. If leak is severe, it may contaminate the clutchdisc.
Lubricant level checkcan 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 lubricantleaks can result in gear, shift rail, synchro, and
bearing damage. The first indications of component damage is usually hardshifting 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 asthe 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.
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 Nꞏm (37 ft. lbs.).

8. Install front dust shield (1) tighten bolt to 4.5 Nꞏm
(40 in. lbs.).
9. Install structural cover (3) to transmission bolts and
tighten to 54 Nꞏm (40 ft. lbs.).
10. Install starter motor (2).
11. Install suspension crossmember (4) and tighten
nuts to 102 Nꞏm (75 ft. lbs.).
12. Connect transmission harnesses to clips on case
and connect switches.
13. Install slave cylinder (2) and tighten cylinder nuts
(1)to23Nꞏm(200in.lbs.).
14. Install transfer case and transfer case linkage if
equipped.
15. Remove transmission jack.
16. Install propeller shaft/shafts with reference marks
aligned.
17. Install exhaust on the exhaust manifolds.
18. Fill transmission with lubricant. Correct fill level is
to bottom edge of fill plug hole.
SPECIFICATIONS
MANUAL TRANSMISSION - GETRAG 238
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm 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 Bolt200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
4x4 Output Shaft Nut200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
Housing Bolts 22 16 -
Interlock Plate Bolts 10 - 88
Intermediate Support Bolts 22 16 -
Intermediate Support Race
Retainer Bolt22 16 -
Countershaft Bolt 90 66 -

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MANUAL TRANSMISSION-T56 - SERVICE
INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - T56 ............. 143
STANDARD PROCEDURE - DRAIN AND FILL . . 143
REMOVAL ................................... 144
DISASSEMBLY .............................. 146
CLEANING .................................. 168
INSPECTION ................................ 168
ASSEMBLY .................................. 169
INSTALLATION .............................. 189
ADJUSTMENTS
ADUSTMENTS ............................ 191
SPECIFICATIONS
MANUAL TRANSMISSION - T56 ............. 192SPECIAL TOOLS ............................ 194
SEAL-EXTENSION HOUSING
REMOVAL ................................... 198
INSTALLATION .............................. 198
SHAFT-INPUT
REMOVAL ................................... 199
INSTALLATION .............................. 200
SOLENOID-REVERSE LOCKOUT
DESCRIPTION ............................... 201
OPERATION ................................. 201
SOLENOID-REVERSE LOCK-OUT
DESCRIPTION ............................... 202
OPERATION ................................. 202

MANUAL TRANSMISSION-T56 - SERVICE INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - T56
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 leakswill be from the oil seals or component mating surfaces.
Front transmission leakswill be from the front bearing retainer or retainer seal. Lubricant may dripfromtheclutch
housing after extended operation. If leak is severe, it may contaminate the clutch disc.
Lubricant level checkcan 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 underfillor 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 lubricantleaks can result in gear, shift rail, synchro, and
bearing damage. The first indications of component damage is usually hardshifting 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 synchro 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, synchros, 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 tail housing
and drain fluid.
3. Install drain plug and tighten to 38 Nꞏm (28 ft. lbs.).
4. Remove transmission fill plug on left side of the
transmission case.
5. Fill transmission to bottom of the fill hole.
6. Install transmission fill plug and tighten to 27 Nꞏm
(20 ft. lbs.).

COUNTERSHAFT BEARINGS PRELOAD
1. Install countershaft with original shim into adapter.
2. Install case and bolt together using all bolts.
3. Rotate countershaft to seat bearings.
4. Screw Stud 8161 into the case and set up dial indi-
cator (1) on the countershaft (2).
5. Zero dial indicator and record end play. If there is
no end play, install .010 in. thinner shim until an
end play is obtained.
6. Once an end play reading is obtained, add end
play number to the shims in the transmission.
7. Install shim(s) behind the countershaft bearing cup
in the front adapter.
SPECIFICATIONS
MANUAL TRANSMISSION - T56
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Adapter Bolts 34 25 -
Back-up Lamp Switch 34 25 -
Dust Shield Bolts 11 - 95
Clutch Release Bearing 20 15 -
Drain Plug 38 28 -
Fill Plug 27 20 -
Flywheel Bolts 74 55 -
Guide Plate Bolts 22 16 -
Inspection Plug 27 20 -
Interlock Bolt 27 20 -
*Reverse Idler Brkt. Bolts 24 18 -
Reverse Lock-Out Bolt 18 13 -
Shifter Assembly 20 15 -
*Shift Detent Assembly 34 25 -
Trans. Top Cover Bolts 20 15 -
Trans. Crossmember Bolts 61 45 -
Trans. Mount Bolts 41 30 -
Trans. To Clutch Cover
Bolts (3/8)35 26 -
Trans. To Eng. Bolts (7/16) 68 50 -
Trans. To Oil Pan (5/16) 23 - 200
* Needs application of Loctite
242

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AUTOMATIC TRANSMISSION 42RLE -
ELECTRICAL DIAGNOSTICS
DIAGNOSIS AND TESTING
P0122-TPS/APP CIRCUIT LOW............. 205
P0123-TPS/APP CIRCUIT HIGH............. 207
P0124-TPS/APP INTERMITTENT ............ 209
P0218-HIGH TEMPERATURE OPERATION
A C T I VAT E D................................ 211
P0562-BATTERY VOLTAGE LOW ............ 213
P0602-CONTROL MODULE PROGRAMMING
ERROR/NOT PROGRAMMED............... 217
P0604-INTERNAL CONTROL MODULE RAM . 218
P0605-INTERNAL CONTROL MODULE ROM . 219
P0613-INTERNAL TRANSMISSION
PROCESSOR.............................. 220
P0706-TRANSMISSION RANGE SENSOR
RATIONALITY............................. 221
P0711-TRANSMISSION TEMPERATURE
SENSOR PERFORMANCE.................. 225
P0712-TRANSMISSION TEMPERATURE
SENSOR LOW............................. 228
P0713-TRANSMISSION TEMPERATURE
SENSOR HIGH............................ 231
P0714-TRANSMISSION TEMPERATURE
SENSOR INTERMITTENT................... 235
P0715-INPUT SPEED SENSOR 1 CIRCUIT . . . 238
P0720-OUTPUT SPEED SENSOR CIRCUIT . . 243
P0725-ENGINE SPEED SENSOR CIRCUIT . . . 248
P0731-GEAR RATIO ERROR IN 1ST ......... 250
P0732-GEAR RATIO ERROR IN 2ND ........ 252
P0733-GEAR RATIO ERROR IN 3RD ........ 254
P0734-GEAR RATIO ERROR IN 4TH ........ 256
P0736-GEAR RATIO ERROR IN REVERSE . . . 258
P0740-TCC OUT OF RANGE ................ 260
P0750-LR SOLENOID CIRCUIT............. 262
P0755-2/4 SOLENOID CIRCUIT ............. 266
P0760-OD SOLENOID CIRCUIT ............. 270
P0765-UD SOLENOID CIRCUIT ............. 274
P0841-LR PRESSURE SWITCH
RATIONALITY............................. 279
P0845-2/4 HYDRAULIC PRESSURE TEST . . . 284
P0846-2/4 PRESSURE SWITCH
RATIONALITY............................. 289
P0868-LINE PRESSURE LOW .............. 294
P0869-LINE PRESSURE HIGH .............. 300
P0870-OD HYDRAULIC PRESSURE TEST . . . 306P0871-OD PRESSURE SWITCH
RATIONALITY.............................. 311
P0882-TCM POWER INPUT LOW ........... 316
P0883-TCM POWER INPUT HIGH ........... 320
P0884-POWER UPAT SPEED .............. 324
P0890-SWITCHED BATTERY ............... 325
P0897-TRANSMISSION FLUID
DETERIORATED........................... 329
P0932-LINE PRESSURE SENSOR CIRCUIT . . 330
P0934-LINE PRESSURE SENSOR CIRCUIT
LOW...................................... 333
P0935-LINE PRESSURE SENSOR CIRCUIT
HIGH..................................... 338
P0944-LOSS OF HYDRAULIC PUMP PRIME . 343
P0992-2/4/OD HYDRAULIC PRESSURE
TEST..................................... 345
P128B-TCM POWER CONTROL CIRCUIT 2
LOW - TIPM............................... 346
P128C-TCM POWER CONTROL CIRCUIT 2
HIGH - TIPM............................... 349
P128D-TCM POWER CONTROL CIRCUIT 2
OPEN - TIPM.............................. 352
P128E-TCM POWER CONTROL CIRCUIT 2
OVERCURRENT - TIPM.................... 355
P1684-BATTERY WAS DISCONNECTED . . . . . 359
P1713-RESTRICTED MANUAL VALVE IN T2
RANGE................................... 362
P1745-TRANSMISSION LINE PRESSURE
TOO HIGH FOR TOO LONG................ 363
P1775-SOLENOID SWITCH VALVE
LATCHED IN TCC POSITION................ 364
P1776-SOLENOID SWITCH VALVE
LATCHED IN LR POSITION................. 369
P1790-FAULT IMMEDIATELY AFTER SHIFT . . 374
P1794-SPEED SENSOR GROUND ERROR . . 375
P1797-MANUAL SHIFT OVERHEAT .......... 378
U0100 LOST COMMUNICATION WITH
ECM/PCM................................. 379
U0002 CAN C BUS OFF PERFORMANCE . . . . 381
U0121 LOST COMMUNICATION WITH ABS . . 383
U0141 LOST COMMUNICATION WITH FCM . . 385
STANDARD PROCEDURE
PRE-DIAGNOSTIC TROUBLESHOOTING
PROCEDURE - 42RLE...................... 387
42RLE TRANSMISSION VERIFICATION
TEST - VER 1............................. 388

P1713-RESTRICTED MANUAL VALVE IN T2 RANGE
For a complete wiring diagramRefer to Section 8W
When Monitored:
Ignition on, engine running with the gear shift selector in a valid forwardgear.
Set Condition:
This DTC sets whenever Transmission control system detects the manual valve is in the T2 range when it
should be in OD. This is mainly an informational DTC.
Possible Causes
RELATED TRANSMISSION DTC’S PRESENT
CUSTOMER DRIVING HABITS
MIS-ADJUSTED SHIFTER CABLE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 42RLE - STANDARD PROCEDURE)
Diagnostic Test
1.DETERMINING IF RELATED DTC’S ARE PRESENT
With the scan tool, check for other transmission DTC’s
Are there any speed sensor or gear ratio DTCs present?
Ye s>>
Refer to the Transmission category and perform the appropriate symptom.
No>>
Go To 2
2.CHECK THE GEAR SHIFT CABLE FOR PROPER ADJUSTMENT
Check the Gear shift cable adjustment per the Service Information.
Also check the cable for possible binding or improperly routed.
Is the Gear shift cable properly adjusted and not binding or improperly routed?
Ye s>>
Go To 3
No>>
Adjust the Shifter Assembly per the Service Information.
Perform 42RLE TRANSMISSION VERIFICATION TEST - VER 1. (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 42RLE - STANDARD PROCEDURE)
3.CHECK CUSTOMER DRIVING HABIT
This DTC can be set if the customer does not move the shift lever completely into the OD position (in between
gears) causing the manual valve to be in the T2 position.
When this occurs, the feed port to the clutch is restricted, the transmission will declare neutral, and this DTC will
set.
This DTC can also be set by simply bumping the shift lever toward neutral while accelerating.
With the scan tool, check the DTC EVENT DATA to help identify the conditionsin which the DTC was set.
If there are no possible causes remaining, view repair.
Repair
This DTC can be set by the shift lever inthe wrong position or not completelyin the OD position. Make
sure the customer is properly informed.
Perform 42RLE TRANSMISSION VERIFICATION TEST - VER 1. (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 42RLE - STANDARD PROCEDURE)