Overview
The ZF 2094.259.024 DISC CARRIER is a precision-machined OEM genuine component engineered for the clutch pack assembly within heavy-duty ZF powershift transmissions. This disc carrier functions as the rotating hub that supports and aligns the friction discs and steel plates, ensuring consistent torque transfer during gear engagement. Located directly on the main shaft cluster, the carrier interfaces with the shift system to manage hydraulic pressure distribution. The SKU 2094.259.024 is manufactured to ZF’s original tolerances, making it a direct replacement for worn units in construction machinery transmissions. When paired with a new 2094104412 MAIN SHAFT, this disc carrier restores the precise axial clearance required for smooth clutch operation.
Symptoms of Failure
- Delayed or harsh gear engagement: A worn disc carrier spline or distorted hub face prevents proper clutch pack alignment, causing noticeable lag or jerky shifts during direction changes.
- Transmission overheating under load: Excessive axial play in the carrier allows clutch discs to slip, generating friction heat that elevates oil temperature beyond normal operating ranges.
- Metallic debris in transmission oil filter: Fretting wear between the carrier and the 2094304054 MAIN SHAFT produces fine steel particles that contaminate the hydraulic circuit.
- Intermittent loss of drive in specific gears: Cracks or fatigue in the carrier’s disc retention lugs cause intermittent clutch pack separation, resulting in momentary power loss under heavy load.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 2094.259.024 |
| Material | Case-hardened alloy steel (16MnCr5 equivalent) |
| Outer Diameter | 180 mm (7.09 in) |
| Inner Spline Diameter | 65 mm (2.56 in) |
| Overall Height | 42 mm (1.65 in) |
| Net Weight | 1.85 kg (4.08 lbs) |
| OEM Reference | ZF 2094.259.024 |
| Surface Treatment | Phosphate coating with oil retention grooves |
Compatibility
This disc carrier is designed for ZF’s WG series powershift transmissions commonly used in wheel loaders, graders, and telehandlers. Based on its spline count and disc stack height, the 2094.259.024 is compatible with the following ZF models: WG180, WG200, WG211, and WG310. It also fits select ERGOPOWER transmissions with similar clutch pack architecture. For proper installation, always inspect the 2094106010 SHIFT SYSTEM for wear on the shift rails and verify the 2094206001 GEARSHIFT SHAFT for straightness before reassembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 2094104412 | MAIN SHAFT | Transfers torque from clutch pack to output gearset |
| 2094304054 | MAIN SHAFT | Alternate spline configuration for WG200 transmissions |
| 2094106010 | SHIFT SYSTEM | Hydraulic valve assembly controlling clutch pressure |
| 2094206001 | GEARSHIFT SHAFT | Mechanical linkage between shift fork and piston |
| 2094306053 | GEARSHIFT SHAFT | Longer variant for multi-speed transmissions |
| 0630513070 | SNAP RING | Secures disc carrier axial position on main shaft |
| 2094306019 | WASHER | Thrust washer for carrier-to-shaft clearance adjustment |
| 0732040444 | COMPRESSION SPRING | Returns shift piston to neutral position |
| 0732040728 | COMPRESSION SPRING | Heavy-duty spring for high-torque clutch packs |
| 2093206001 | BUSH | Guides gearshift shaft through transmission housing |
Frequently Asked Questions
Q: Can I reuse the old snap ring when installing a new disc carrier?
A: No. The snap ring (part 0630513070) should always be replaced during carrier installation. Reusing a fatigued snap ring can allow axial movement of the carrier, leading to clutch pack misalignment and premature failure.
Q: How do I confirm the 2094.259.024 fits my ZF WG180 transmission?
A: Measure the inner spline diameter of your existing carrier. The 2094.259.024 uses a 65 mm spline bore with 24 teeth. If your transmission uses a different spline count, you may need the alternate main shaft (2094304054) to match the carrier interface.
Q: What torque specification applies to the main shaft nut when securing this carrier?
A: ZF specifies 320 Nm (236 ft-lbs) for the main shaft retaining nut on WG series transmissions. Always use a new lock washer and apply thread locker to prevent loosening under vibration.
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Phone: +86 158 2286 3467 |
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