Overview
The ZF 4616.000.155 4 WG 65 Powershift Transmission Assembly is a complete, factory-grade unit designed for heavy-duty off-highway applications. This assembly integrates the full clutch pack, planetary gear set, and hydraulic control system into a single, ready-to-install package. As a core component of the WG 65 Series, the SKU 4616.000.155 serves as the primary power transfer module, converting engine torque into smooth, multi-speed output for wheel loaders, graders, and industrial tractors. It sits directly between the engine bell housing and the final drive, requiring precise alignment with the 4616101059: TRANSMISSION HOUSING to ensure proper oil flow and structural integrity.
Symptoms of Failure
- Erratic gear engagement and slipping under load: Worn clutch discs or degraded seals inside the 4616.000.155 cause delayed shifts or complete loss of drive in specific ranges, especially during uphill operation.
- External oil leaks at the housing joint: Cracks or warpage in the assembly body force hydraulic fluid past the 0636011038: HEXAGON SCREW and 0636011118: HEXAGON SCREW mounting points, leaving visible puddles under the machine.
- Metallic grinding noise during gear changes: Failed bearings or planetary gear damage within the unit produce a distinct whine or chatter, worsening as the transmission temperature rises.
- Low hydraulic pressure warnings: Internal leakage past the valve body or piston seals triggers dash alarms, often accompanied by sluggish response when shifting from forward to reverse.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.000.155 |
| Assembly Type | Complete Powershift Unit (4-speed) |
| Dry Weight | Approx. 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| OEM Reference | ZF 4616.000.155 (Direct replacement) |
| Mounting Hardware | 0636016015: HEXAGON SCREW (x8 required) |
| Sealing Kit | Includes 0634313118: O-RING and 0634801152: SEALING RING |
Compatibility
This complete unit is engineered for the ZF WG 65 Series transmission family. It is a direct fit for models including the WG180, WG200, and WG220 used in articulated dump trucks and heavy loaders. The 4616.000.155 also retrofits into earlier WG150 and WG160 housings when paired with the correct 0631306085: CYLINDRICAL PIN alignment kit. Always verify the clutch pack count and valve body configuration against your original unit before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101059 | TRANSMISSION HOUSING | Encloses the gear train and oil sump |
| 0636011038 | HEXAGON SCREW | Secures housing to bell housing |
| 0636011118 | HEXAGON SCREW | Mounts the valve body cover |
| 0636016015 | HEXAGON SCREW | Fastens the clutch pack retainer |
| 0631306085 | CYLINDRICAL PIN | Aligns housing halves during assembly |
| 0634313118 | O-RING | Seals the main pressure port |
| 0636304019 | SCREW PLUG | Closes the oil drain port |
| 0634801152 | SEALING RING | Prevents leakage at the output shaft |
| 0732611049 | FILTER INSERT | Captures debris in the hydraulic circuit |
| 0634303718 | O-RING | Seals the filter housing cap |
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