Overview
The ZF 0501.005.402 CLUTCH BOOSTER is a critical pneumatic-hydraulic assist device designed to reduce pedal effort in heavy-duty ZF transmissions. Positioned between the clutch pedal master cylinder and the clutch release fork, this OEM genuine part amplifies driver input to ensure smooth, consistent clutch disengagement. The SKU 0501.005.402 is engineered specifically for the WG100, WG130, and WG131 series, providing reliable force multiplication in demanding industrial applications. When paired with a robust DIFFERENTIAL assembly, this booster maintains precise hydraulic control under high torque loads.
Symptoms of Failure
- Hard clutch pedal with intermittent sticking: A worn booster reduces hydraulic assist, requiring excessive leg force and causing the pedal to hang mid-travel.
- External hydraulic fluid leakage: Deteriorated seals around the booster body lead to visible oil drips near the bell housing, often mistaken for transmission leaks.
- Delayed clutch engagement or gear grinding: Insufficient boost pressure prevents full clutch release, causing harsh shifts and premature wear on the TAPER ROLLER BEARING in the input shaft.
- Air ingestion in hydraulic circuit: Failed internal diaphragms introduce bubbles into the system, resulting in a spongy pedal feel and inconsistent clutch modulation.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 0501.005.402 |
| Material | Die-cast aluminum housing with nitrile rubber seals |
| Weight | 1.85 kg (4.08 lbs) |
| Overall Length | 215 mm |
| Bore Diameter | 32 mm |
| Maximum Operating Pressure | 12 bar (174 psi) |
| Fluid Type | DOT 4 or ZF-approved mineral oil |
| Thread Size | M10 x 1.5 (inlet/outlet ports) |
| Operating Temperature Range | -40°C to +120°C |
| OEM Reference | ZF 0501.005.402 |
Compatibility
This clutch booster is factory-specified for ZF WG100, WG130, and WG131 transmissions. It also retrofits to earlier WG180 and WG200 series units when used with the correct mounting bracket. For optimal driveline integrity, always inspect the DIFFERENTIAL and DIFFERENTIAL HOUSING for wear during booster replacement, as hydraulic imbalances can accelerate component fatigue.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 5838109012 | DIFFERENTIAL | Distributes torque between drive wheels |
| 0750117075 | TAPER ROLLER BEARING | Supports axial and radial loads on shafts |
| 2093209023 | DIFFERENTIAL | Alternate differential assembly for WG series |
| 5838300626 | DIFFERENTIAL HOUSING | Encloses differential gears and bearings |
| 0631329088 | SPRING PIN | Secures linkage pins in clutch mechanism |
| 5838300811 | THRUST WASHER | Reduces friction between rotating gears |
| 5838300721 | AXLE BEVEL GEAR | Transfers power to axle shafts |
| 5838300633 | AXLE | Connects differential to wheel hubs |
| 5838300753 | THRUST WASHER | Prevents axial gear movement |
| 5838300818 | THRUST WASHER | Additional axial load distribution |
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