Overview
The ZF 4616.199.153 LOOSE PARTS kit is a critical service component designed specifically for the WG 65 Series transmission. This genuine OEM assembly contains the necessary fasteners, seals, and positioning elements required to secure the output section of the gearbox. As a loose parts set, it ensures that the 4616105402: OUTPUT and the 4005303005: OUTPUT FLANGE remain correctly torqued and aligned within the 4616101119: TRANSMISSION HOUSING. The SKU 4616.199.153 is often ordered during a major overhaul to replace all single-use hardware in one convenient package, eliminating the need to source individual bolts and washers separately.
Symptoms of Failure
- Oil seepage at the output flange joint: When the loose parts kit components wear or loosen, the seal between the output flange and housing fails, leading to visible transmission fluid drips under the vehicle.
- Audible clunking during gear engagement: Worn fasteners from the 4616.199.153 kit can allow the output shaft assembly to develop axial play, producing a metallic knock when shifting from neutral to drive or reverse.
- Vibration at highway speeds: If the hexagon screws in this kit lose their clamping force, the output flange may wobble slightly, transmitting vibration through the driveline at 40-60 mph.
- Difficulty maintaining gear position: A loose transmission housing connection due to degraded hardware can cause the shift mechanism to feel imprecise, with the transmission occasionally slipping out of gear under load.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.199.153 |
| Material Composition | Steel (fasteners) / NBR (seals) |
| Weight (approx.) | 0.85 kg (1.87 lbs) |
| OEM Reference | ZF 4616.199.153 |
| Included Components | Hexagon screws, O-rings, sealing rings, cylindrical pins |
| Thread Size (primary bolt) | M10 x 1.5 |
| Torque Specification | 45 Nm + 90° (per ZF manual) |
Compatibility
This loose parts kit is engineered for the ZF WG 65 Series transmission family. Based on the part type and fastener configuration, it is compatible with the following ZF models: WG65, WG120, WG180, and WG200. The 4616.199.153 kit is also suitable for use in select off-highway and industrial ZF gearboxes that share the same output housing bolt pattern. Always verify your transmission serial number before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616105402 | OUTPUT | Transfers torque from planetary gears to output flange |
| 4005303005 | OUTPUT FLANGE | Connects transmission to driveshaft |
| 4616101119 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 0636011038 | HEXAGON SCREW | Secures output flange to shaft |
| 0636011118 | HEXAGON SCREW | Mounts housing to bell housing |
| 0636016015 | HEXAGON SCREW | Fastens cover plate |
| 0631306085 | CYLINDRICAL PIN | Aligns housing halves during assembly |
| 0634313118 | O-RING | Seals oil passages between housing sections |
| 0636304019 | SCREW PLUG | Closes inspection port |
| 0634801152 | SEALING RING | Prevents fluid leakage at plug threads |
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