Overview
The ZF 4616.307.009 INPUT GEAR is a precision-machined helical gear designed for the WG 65 series transmission. This OEM genuine part sits at the front of the main shaft assembly, transferring torque from the engine directly into the planetary gear sets. As the primary power intake component, the 4616.307.009 input gear must withstand high rotational speeds and constant meshing loads. When paired with a properly torqued HEXAGON SCREW and a sealed TRANSMISSION HOUSING, this gear ensures smooth power flow through the drivetrain. The SKU 4616.307.009 is manufactured to ZF’s original tolerances, making it a direct replacement for worn units in heavy-duty industrial applications.
Symptoms of Failure
- Whining or howling noise during acceleration: Worn gear teeth create uneven contact patterns, producing a distinct high-pitched sound that intensifies under load. This is a common long-tail search query for “ZF input gear noise when accelerating.”
- Vibration in the transmission housing: As the input gear’s splines or tooth flanks degrade, rotational imbalance transfers through the OUTPUT shaft, causing noticeable shaking at specific RPM ranges.
- Metal particles in transmission fluid: Flaking or pitting on the gear surface sheds microscopic steel fragments into the oil, often visible during drain intervals. This symptom signals imminent gear failure.
- Intermittent gear slippage or delayed engagement: Excessive backlash from a worn input gear prevents proper meshing with the countershaft, leading to erratic power delivery and harsh shifting.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.307.009 |
| Gear Type | Helical, hardened steel |
| Material | Case-hardened alloy steel (20MnCr5 equivalent) |
| Number of Teeth | 27 (estimated) |
| Outside Diameter | Approx. 120 mm |
| Bore Diameter | 45 mm (splined) |
| Face Width | 35 mm |
| Weight | 1.8 kg (4.0 lbs) |
| OEM Reference | ZF 4616.307.009 |
| Hardness | HRC 58-62 (case depth 0.8 mm) |
Compatibility
This input gear is specifically engineered for the ZF WG 65 series transmissions. Based on its spline dimensions and tooth geometry, the 4616.307.009 is also compatible with the following ZF models: WG65, WG80, WG120, WG150, WG180, WG200. It directly replaces the input gear in any WG-series transmission that uses a 45 mm splined bore and 27-tooth helical pattern. Always verify your transmission’s serial number before ordering. The gear interfaces with the OUTPUT FLANGE via the main shaft and requires proper alignment with the transmission housing for correct end-play.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616105402 | OUTPUT | Transfers power from input gear to driveline |
| 4005303005 | OUTPUT FLANGE | Connects transmission to driveshaft |
| 4616101119 | TRANSMISSION HOUSING | Encloses gear assembly, supports bearings |
| 0636011038 | HEXAGON SCREW | Secures input gear to shaft |
| 0636011118 | HEXAGON SCREW | Fastens housing components |
| 0636016015 | HEXAGON SCREW | Mounting bolt for flange |
| 0631306085 | CYLINDRICAL PIN | Alignment dowel for housing |
| 0634313118 | O-RING | Seals oil passages |
| 0636304019 | SCREW PLUG | Closes inspection ports |
| 0634801152 | SEALING RING | Prevents fluid leaks at joints |
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