Page 2657 of 5267

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 -
Page 2658 of 5267
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Reverse Idler Gear Shaft
Bolt25 18 -
Mainshaft, Countershaft
Bearing Retainer Bolts10 - 88
Input Shaft Retainer Bolts 10 - 88
Shift Fork Pivot Bolts 35 26 -
Support Braket to Trans
Bolts54 40 -
GEAR SPECIFICATIONS
GEAR RATIO
FIRST 4.23
SECOND 2.53
THIRD 1.67
FOURTH 1.23
FIFTH 1.00
SIXTH 0.79
REVERSE 3.84
Page 2659 of 5267
SPECIAL TOOLS
INSTALLER C-3717
SLIDE HAMMER C-3752
SLIDE HAMMER C-637
INSTALLER D-389
INSTALLER W-262
INSTALLER 8475
PULLER 8870
PULLER 8992
Page 2660 of 5267
BRIDGE 938
PULLER 9583
SOCKET 9584
PULLER 9585
WRENCH 9586
PULLER 9609
REMOVER/INSTALLER 9617
PULLER 9618
Page 2661 of 5267
BUTTON 9618-2
HEAT PLUG 9619-1 & 9619-2
INSTALLER 9620
PULLER 9621
INSTALLER 9622
INSTALLER 9624
HEAT PLUG 9625
FIXTURE 9626
Page 2662 of 5267
PULLER ADAPTER 9627
PULLER ADAPTER 9628
INSTALLER 9629
REMOVER 9667
REMOVER/INSTALLER 9668
Page 2663 of 5267

page page
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
Page 2664 of 5267

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.).