Overview
The ZF 4616.000.259 4 WG 65 Powershift Transmission Assembly | Complete Unit is a fully assembled drop-in replacement for heavy-duty off-highway vehicles. This complete unit integrates the clutch packs, planetary gear sets, and hydraulic control system into a single, pre-tested assembly. The SKU 4616.000.259 designates a specific revision of the WG 65 series, ensuring correct gear ratios and torque capacity for mid-range loaders and graders. It mounts directly to the engine bell housing and transfers power through the driveline, with the TRANSMISSION HOUSING providing the structural foundation for all internal components.
Symptoms of Failure
- Delayed or harsh engagement: When the unit wears, hydraulic pressure drops, causing a noticeable lag when shifting from neutral to forward or reverse. This often accompanies a loud clunk as gears engage.
- Torque converter shudder: A vibration felt through the chassis during acceleration under load, indicating worn clutch discs or a failing stator within the assembly.
- External oil seepage at mating flanges: Leaks develop around the joint between the main housing and the HOUSING or the HOUSING sections, often due to degraded gaskets or overtightened fasteners.
- Erratic shifting under load: The transmission may skip gears or fail to hold a selected gear when pushing heavy material, a sign of internal seal failure or valve body contamination.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4616.000.259 |
| Series | WG 65 (4 WG 65) |
| Dry Weight (approx.) | 285 kg (628 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 580 mm |
| Housing Material | Cast Iron (GGG-40) |
| Torque Capacity | 650 Nm (479 lb-ft) |
| Number of Speeds | 4 Forward / 4 Reverse |
| Mounting Bolt Pattern | SAE 3 (with HEXAGON SCREW M12 x 1.75) |
Compatibility
This complete unit is engineered for the ZF WG 65 series, which includes the WG65, WG80, and WG100 variants used in compact wheel loaders and telehandlers. It is also backward-compatible with earlier 4 WG 65 models after verifying the input shaft spline count. The assembly requires the HEXAGON SCREW kit for secure mounting to the engine adapter plate. For full rebuilds, the TRANSMISSION HOUSING and both HOUSING sections must be inspected for cracks before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101137 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 0636011118 | HEXAGON SCREW | Fastener for housing assembly |
| 4616301304 | HOUSING | Rear cover housing for clutch pack |
| 4616301309 | HOUSING | Intermediate housing section |
| 0630361069 | SEALING CAP | Prevents oil leakage from ports |
| 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 | Seals hydraulic passages between housings |
| 0636304019 | SCREW PLUG | Closes oil drain or test ports |
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