Overview
The ZF 0501.008.238 SYNCHRONIZER is a precision-engineered OEM genuine part designed to facilitate smooth gear engagement within heavy-duty construction machinery transmissions. This component sits directly within the transmission’s synchronizer assembly, where it equalizes rotational speeds between the gear and shaft before locking them together. By reducing shift shock and preventing gear clash, the 0501.008.238 ensures reliable power transfer under high-torque conditions. The SKU 0501.008.238 is manufactured to ZF’s exacting tolerances, making it a critical element for maintaining drivetrain integrity in demanding off-road environments.
Symptoms of Failure
- Grinding or clashing noises during gear shifts — When the synchronizer wears, it fails to match shaft speeds, causing audible metal-on-metal contact. This is a common sign of a failing ZF 0501.008.238.
- Hard shifting or gear lockout — Operators may struggle to engage a specific gear, particularly under load. Worn synchronizer rings prevent smooth sliding sleeve movement.
- Transmission jumping out of gear — A degraded synchronizer can no longer hold the gear in position, leading to unexpected disengagement during operation.
- Increased shift effort over time — Gradual wear on the synchronizer hub and cone surfaces requires more force to complete a shift, often accompanied by a delayed engagement.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number | 0501.008.238 |
| Material | Case-hardened steel with brass synchronizer ring |
| Outer Diameter | Approx. 120 mm |
| Inner Diameter | Approx. 65 mm |
| Height | 32 mm |
| Weight | 0.85 kg |
| OEM Reference | ZF 0501.008.238 |
| Thread Pitch | M8 x 1.25 (mounting bolts) |
Compatibility
This synchronizer is primarily used in ZF’s WG180 and WG200 series transmissions, which are common in wheel loaders, graders, and other construction machinery. It also fits select WG150 and WG210 variants where the synchronizer assembly shares the same spline count and cone angle. Always verify your transmission model’s parts manual before ordering. For a complete overhaul, consider pairing this synchronizer with the 5838109021 DIFFERENTIAL and the 0750117075 TAPER ROLLER BEARING to ensure optimal alignment. Additionally, the 2095209019 DIFFERENTIAL and 0631329086 SPRING PIN are frequently replaced during synchronizer service to prevent future failures.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 5838109021 | DIFFERENTIAL | Distributes torque between axles |
| 0750117075 | TAPER ROLLER BEARING | Supports rotating shafts under axial loads |
| 2095209019 | DIFFERENTIAL | Secondary differential for planetary drives |
| 0631329086 | SPRING PIN | Secures synchronizer hub to shaft |
| 5838300817 | THRUST WASHER | Reduces axial friction in gear sets |
| 5838300682 | DIFFERENTIAL AXLE | Transfers power to wheel hubs |
| 5838300811 | THRUST WASHER | Controls end-play in planetary gears |
| 5841302064 | THRUST WASHER | Provides wear surface for clutch packs |
| 5838300812 | SEALING RING | Prevents oil leakage between shafts |
| 5838300137 | OUTER CLUTCH DISK | Engages and disengages power flow |
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