Overview
The ZF 4616.108.018 COUNTERSHAFT is a critical internal component engineered for the WG 65 Series transmission family. This genuine OEM part serves as the primary torque-transfer shaft, meshing directly with multiple gear sets to facilitate smooth ratio changes under heavy load. Located within the main gear cluster, the countershaft (SKU: 4616.108.018) ensures precise alignment of rotating elements, directly influencing shift quality and overall drivetrain efficiency. It is typically secured within the 4616101066: TRANSMISSION HOUSING and works in concert with the 4616301307: HOUSING to maintain structural integrity under extreme torque.
Symptoms of Failure
- Gear Slipping Under Load: Worn splines or bearing journals on the countershaft cause intermittent disengagement, especially during uphill hauls or high-torque acceleration.
- Abnormal Gear Whine or Grinding: A failing countershaft produces a distinct, high-pitched whine that escalates to a grinding noise as the shaft surface degrades.
- Metal Particles in Transmission Fluid: Flaking or spalling from the hardened shaft surface contaminates the oil, often visible during routine drain intervals.
- Hard Shifting or Gear Lockout: Misalignment due to a bent or worn countershaft prevents smooth engagement, requiring excessive force to shift.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.108.018 |
| OEM Reference | ZF 4616.108.018 |
| Material | Case-hardened alloy steel (20MnCr5 equivalent) |
| Overall Length | ~ 420 mm |
| Journal Diameter | ~ 55 mm |
| Weight | ~ 8.2 kg |
| Spline Count | 24 involute splines |
| Heat Treatment | Carburized & tempered to HRC 58-62 |
Compatibility
This countershaft is specifically designed for the ZF WG 65 Series transmissions, including models such as WG65, WG80, WG100, WG120, WG150, WG180, and WG200. It is a direct replacement for OEM assemblies where the shaft interfaces with the 4616301309: HOUSING and is retained by 0636011118: HEXAGON SCREW fasteners. Always verify your transmission model suffix before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101066 | TRANSMISSION HOUSING | Encloses and supports the countershaft assembly |
| 0636011118 | HEXAGON SCREW | Secures bearing caps and housing sections |
| 4616301307 | HOUSING | Intermediate support housing for gear cluster |
| 4616301309 | HOUSING | Rear housing section for countershaft alignment |
| 0636011038 | HEXAGON SCREW | Fastener for flange connections |
| 0636016015 | HEXAGON SCREW | High-torque fastener for main housing |
| 0631306085 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0634313118 | O-RING | Seals fluid passages between housings |
| 0636304019 | SCREW PLUG | Closes oil drain or fill ports |
| 0634801152 | SEALING RING | Prevents fluid leaks at threaded joints |
