Overview
The ZF 4661.203.006 OUTPUT FLANGE is a critical driveline component engineered for the WG 94 series transmission family. 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. Positioned at the rear of the transmission housing, the output flange ensures precise alignment and secure coupling under high-load conditions. The SKU 4661.203.006 is a direct replacement for original equipment, guaranteeing factory tolerances and material integrity. This flange works in concert with the 4661101037: TRANSMISSION HOUSING and the 4661301099: HOUSING II to maintain structural rigidity within the assembly.
Symptoms of Failure
When the ZF 4661.203.006 output flange deteriorates, operators typically encounter these specific failure indicators:
- Transmission oil leaks at the rear seal area – Worn flange splines or a damaged sealing surface allow fluid to escape, often visible as drips near the driveshaft connection.
- Driveline vibration during acceleration – A loose or worn output flange creates imbalance, transmitting shudder through the chassis at highway speeds.
- Gear engagement hesitation or clunking – Excessive play between the flange and output shaft causes delayed power transfer, particularly when shifting from neutral to drive.
- Metallic debris in transmission fluid – Flange material wear generates fine metal particles, detectable during routine oil changes.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4661.203.006 |
| OEM Reference | ZF 4661.203.006 |
| Material | Forged alloy steel, induction-hardened |
| Weight | 2.85 kg (6.28 lbs) |
| Outer Diameter | 120 mm |
| Bolt Circle Diameter | 95 mm |
| Spline Count | 24 internal splines |
| Surface Treatment | Zinc-nickel plating, corrosion resistant |
| Torque Capacity | 1,200 Nm (885 ft-lbs) |
Compatibility
This output flange is designed primarily for the ZF WG 94 series transmissions, including models WG94, WG180, and WG200. It is also compatible with select WG 92 and WG 96 variants that share the same output shaft spline pattern. Always verify the spline count and bolt pattern against your specific transmission model. For complete assembly integrity, inspect the 0631306174: CYLINDRICAL PIN and the 0769123894: TYPE PLATE during installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101037 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4661301099 | HOUSING II | Rear housing section supporting output shaft |
| 0631306174 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0769123894 | TYPE PLATE | Identification tag with transmission specs |
| 0750100022 | SCREW PLUG | Seals oil passages in housing |
| 4660201008 | SCREW PLUG | Magnetic drain plug for debris capture |
| 0636100117 | SCREW PLUG | Pressure test port plug |
| 0501211384 | VALVE | Hydraulic control valve for clutch modulation |
| 0732042156 | COMPRESSION SPRING | Returns valve spool to neutral position |
| 0768409154 | SCREW PLUG | Oil gallery sealing plug |
