Overview
The ZF 4616.000.253 4 WG 65 Powershift Transmission Assembly | Complete Unit is a fully assembled drop-in solution for heavy-duty off-highway machinery. This complete unit integrates the clutch packs, planetary gear sets, and hydraulic control system into a single, ready-to-install package. As the core of the WG 65 series, it manages torque distribution across four forward and reverse speeds, enabling smooth directional shifts under load. The SKU 4616.000.253 designates a factory-spec assembly, ensuring direct compatibility with existing driveline components. For structural integrity, this unit mounts directly to the 4616101137: TRANSMISSION HOUSING, which provides the rigid foundation for all rotating elements.
Symptoms of Failure
- Delayed or harsh engagement — When the assembly wears, internal clutch packs slip, causing a noticeable lag between gear selection and actual movement, often accompanied by a jarring shift.
- Low hydraulic pressure warnings — Internal seal degradation leads to pressure loss, triggering dashboard alarms and preventing the transmission from holding a gear under load.
- Metallic grinding noises — Worn bearings or planetary gears produce a distinct whining or grinding sound, particularly during acceleration or deceleration.
- External oil seepage — Cracks in the housing or failed gaskets allow ATF to escape, leaving visible puddles and reducing lubrication capacity.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4616.000.253 |
| Assembly Type | Complete Powershift Unit (4 WG 65) |
| Dry Weight | Approx. 185 kg (408 lbs) |
| Housing Material | High-strength cast iron (GGG-40) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Bolt Torque Spec | M16: 210 Nm (use 0636011118: HEXAGON SCREW) |
| Sealing Cap | 0630361069: SEALING CAP |
| O-Ring | 0634313118: O-RING |
| Dowel Pin | 0631306085: CYLINDRICAL PIN |
| Drain Plug | 0636304019: SCREW PLUG |
Compatibility
This assembly is engineered for the WG 65 Series powershift family, which includes models such as WG180, WG200, and WG250. It is also backward-compatible with earlier 4 WG 65 variants used in ZF’s ERGOPOWER and ECOMIX lines. The unit integrates with the 4616301304: HOUSING and 4616301309: HOUSING to form the complete gearbox casing. Always verify the bellhousing pattern and input spline count before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101137 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 0636011118 | HEXAGON SCREW | M16 bolt for housing attachment |
| 4616301304 | HOUSING | Rear cover housing for output shaft |
| 4616301309 | HOUSING | Front housing for clutch pack support |
| 0630361069 | SEALING CAP | Prevents debris ingress into vent ports |
| 0636011038 | HEXAGON SCREW | M12 bolt for valve body mounting |
| 0636016015 | HEXAGON SCREW | M20 bolt for PTO adapter |
| 0631306085 | CYLINDRICAL PIN | Alignment dowel for housing halves |
| 0634313118 | O-RING | Seals hydraulic passages between housings |
| 0636304019 | SCREW PLUG | Magnetic drain plug for oil pan |
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