Overview
The ZF 4660.203.005 Output Flange is a critical driveline component engineered for the WG200 and WG92 series transmissions. This OEM genuine part serves as the mechanical interface between the transmission output shaft and the driveshaft, transferring rotational torque from the gearbox to the vehicle’s wheels. Manufactured to ZF’s exacting tolerances, the 4660.203.005 ensures precise alignment and vibration-free power delivery. It mounts directly onto the output shaft within the 4660101011: TRANSMISSION HOUSING, where it is secured by a 0636103273: CAP SCREW and sealed with a 0634100317: O-RING to prevent fluid loss.
Symptoms of Failure
- Transmission fluid leaking from the output shaft seal area — A worn or cracked output flange allows oil to seep past the seal, leaving puddles under the vehicle and reducing lubrication levels.
- Driveshaft vibration during acceleration — Spline wear or flange distortion causes imbalance, producing a rhythmic shudder felt through the chassis at highway speeds.
- Clunking noise when shifting between drive and reverse — Excessive backlash in the flange splines creates a metallic impact sound during gear engagement.
- Premature bearing failure in the transmission housing — A loose output flange transfers axial loads to the 4660301018: HOUSING, accelerating wear on internal bearings.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4660.203.005 |
| OEM Reference | ZF 4660.203.005 |
| Material | Forged steel, induction-hardened |
| Outer Diameter | 120 mm (approx.) |
| Overall Length | 85 mm (approx.) |
| Spline Count | 14-tooth internal spline |
| Weight | 1.8 kg (approx.) |
| Torque Capacity | 2,500 Nm (estimated) |
Compatibility
This output flange is specifically designed for the ZF WG200 and WG92 series transmissions. Based on its spline geometry and bolt pattern, it is also compatible with the WG180 series and certain WG210 variants. The flange interfaces directly with the 4660101804: TRANSMISSION HOUSING and works in conjunction with the 4660221012: SUCTION TUBE for proper oil circulation. Always verify your transmission model number against the 0769123894: TYPE PLATE before installation. The flange is secured using a 0750100022: SCREW PLUG and a 0631306174: CYLINDRICAL PIN for alignment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4660101011 | TRANSMISSION HOUSING | Encloses gear train and supports output shaft |
| 4660301018 | HOUSING | Rear housing section for bearing support |
| 0631306174 | CYLINDRICAL PIN | Aligns flange to shaft during assembly |
| 0769123894 | TYPE PLATE | Identification plate with transmission specs |
| 4660221012 | SUCTION TUBE | Draws oil from sump to pump |
| 0634100317 | O-RING | Seals flange-to-housing joint |
| 0636103273 | CAP SCREW | Fastens flange to output shaft |
| 0750100022 | SCREW PLUG | Seals oil passage in housing |
| 4660101804 | TRANSMISSION HOUSING | Alternate housing variant for WG200 |
| 4660301008 | HOUSING | Alternate rear housing for WG92 |
