Overview
The ZF 4616.000.254 4 WG 65 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway machinery. As the core hydraulic-mechanical assembly in the WG 65 Series, this unit integrates the clutch packs, planetary gear sets, and valve body into a single, ready-to-install package. The SKU 4616.000.254 specifically denotes a remanufactured or new complete assembly, ensuring precise gear engagement under high torque loads. It sits directly between the engine bellhousing and the output driveline, requiring a secure TRANSMISSION HOUSING to maintain alignment and structural integrity during operation.
Symptoms of Failure
- Delayed or harsh engagement: When the internal clutch packs wear, operators experience a noticeable lag or a jarring “clunk” when shifting from neutral to forward or reverse.
- Intermittent gear slipping under load: A worn assembly loses hydraulic pressure, causing the transmission to momentarily lose power on inclines or during heavy digging cycles.
- External oil seepage at mating surfaces: Degraded seals within the unit allow ATF to weep from the joint between the assembly and the HOUSING, leaving visible drips on the chassis.
- Unusual whining or grinding noises: Bearing wear inside the assembly produces a high-pitched whine that increases with engine RPM, often accompanied by metallic debris in the oil filter.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4616.000.254 |
| Assembly Type | Complete Powershift Unit (4 WG 65) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-Grade Cast Iron |
| Clutch Disc Material | Sintered Bronze on Steel |
| Max Input Torque | 1,200 Nm |
| Fluid Capacity (system) | 18.5 Liters |
| Mounting Bolt Torque | 120 Nm (M12 bolts) |
Compatibility
This complete assembly is engineered for the WG 65 Series powershift transmissions. It is directly compatible with models including the WG180, WG200, and WG250 used in wheel loaders, forklifts, and telehandlers. The unit interfaces with the HOUSING (rear section) and is secured using HEXAGON SCREW fasteners at the bellhousing flange. Always verify your transmission serial number against the WG 65 family before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101140 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 0636011118 | HEXAGON SCREW | Fastener for housing-to-bellhousing joint |
| 4616301304 | HOUSING | Rear cover housing for output shaft |
| 4616301309 | HOUSING | Intermediate housing for clutch pack |
| 0636011038 | HEXAGON SCREW | M10 bolt for valve body mounting |
| 0636016015 | HEXAGON SCREW | M16 bolt for torque converter housing |
| 0631306085 | CYLINDRICAL PIN | Alignment dowel for housing halves |
| 0634313118 | O-RING | Seal between housing and valve plate |
| 0636304019 | SCREW PLUG | Oil drain plug for sump access |
| 0634801152 | SEALING RING | Copper crush washer for plug seal |
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