Overview
The ZF 4616.108.040 COUNTERSHAFT is a critical internal component within the WG 65 Series transmission, responsible for transferring rotational force from the input shaft to the output shaft via a series of gear sets. This OEM genuine part ensures precise gear alignment and torque distribution, directly influencing the transmission’s overall efficiency and load-bearing capacity. The SKU 4616.108.040 is engineered to exact ZF specifications, providing a direct replacement for worn units in heavy-duty commercial vehicles. When installed, it works in concert with the 4616105402: OUTPUT to manage power flow, and it is housed within the 4616101119: TRANSMISSION HOUSING, which protects the assembly from debris and stress.
Symptoms of Failure
When the countershaft wears out, operators often notice distinct performance issues. Gear slipping under heavy load is a primary symptom, as the countershaft’s splines lose engagement with mating gears. Another common failure sign is abnormal whining or grinding noises during gear changes, indicating bearing surface degradation on the shaft. Oil leaks near the transmission housing can also occur if the countershaft’s seals are compromised, leading to fluid loss and potential overheating. Finally, difficulty shifting into specific gears may arise from misalignment caused by a bent or worn countershaft, a problem that often requires replacing the 4005303005: OUTPUT FLANGE and related fasteners like the 0636011038: HEXAGON SCREW during repair.
Technical Specifications
| Specification | Details |
|---|---|
| Part Number | 4616.108.040 |
| Material | Case-hardened alloy steel (EN 10084) |
| Overall Length | ~ 420 mm |
| Diameter (bearing journals) | ~ 55 mm |
| Weight | ~ 8.2 kg |
| OEM Reference | ZF 4616.108.040 |
| Surface Treatment | Nitrided for wear resistance |
Compatibility
This countershaft is specifically designed for the WG 65 Series transmission family, which includes models such as the WG180, WG200, and WG250. These transmissions are commonly found in heavy-duty trucks, buses, and construction equipment. The part also interfaces with the WG 65 and WG 65-2 variants, ensuring broad coverage for fleet maintenance. For complete assembly, it is essential to pair this shaft with the correct 0636011038: HEXAGON SCREW for secure mounting within the housing.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616105402 | OUTPUT | Transfers torque from countershaft to driveline |
| 4005303005 | OUTPUT FLANGE | Connects output shaft to driveshaft |
| 4616101119 | TRANSMISSION HOUSING | Encloses and supports internal gears and shafts |
| 0636011038 | HEXAGON SCREW | Secures countershaft bearing caps |
| 0636011118 | HEXAGON SCREW | Fastens housing cover plates |
| 0636016015 | HEXAGON SCREW | Mounts output flange to shaft |
| 0631306085 | CYLINDRICAL PIN | Aligns housing halves during assembly |
| 0634313118 | O-RING | Seals oil passages between housing sections |
| 0636304019 | SCREW PLUG | Closes inspection ports in housing |
| 0634801152 | SEALING RING | Prevents oil leaks at shaft exits |
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