Overview
The ZF 4616.203.017 OUTPUT FLANGE is a critical driveline component engineered specifically for the WG 65 Series transmission. This OEM genuine part serves as the mechanical interface between the transmission output shaft and the propeller shaft or drive axle, transferring rotational torque from the gearbox to the vehicle’s wheels. Machined from high-strength forged steel, the flange ensures precise alignment and vibration-free power delivery under heavy loads. The SKU 4616.203.017 is a direct replacement for the original factory component, guaranteeing exact fitment and durability. When installed alongside the 4616105413: OUTPUT assembly, this flange completes the torque path, while the 4616101117: TRANSMISSION HOUSING provides the structural enclosure. Secure mounting is achieved using the 0636011038: HEXAGON SCREW and 0636016015: HEXAGON SCREW fasteners, which must be torqued to specification during installation.
Symptoms of Failure
- Transmission fluid seepage at the flange hub: A worn or cracked output flange often causes oil to weep around the seal area, leading to low fluid levels and potential gearbox damage.
- Vibration or shudder during acceleration: A loose or damaged flange can create driveline imbalance, resulting in noticeable shaking that worsens at higher speeds.
- Clunking noise when shifting gears: Excessive play between the flange splines and output shaft produces metallic knocking sounds, especially during load changes.
- Premature wear of the output shaft bearing: A misaligned flange transfers abnormal forces to the bearing, causing early failure and potential transmission seizure.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.203.017 |
| OEM Reference | ZF 4616.203.017 |
| Material | Forged steel, heat-treated |
| Outer Diameter | 180 mm (approx.) |
| Inner Spline Diameter | 45 mm (approx.) |
| Overall Length | 85 mm (approx.) |
| Bolt Hole Pattern | 8 x M12 on 150 mm PCD |
| Weight | 2.4 kg (approx.) |
| Surface Finish | Zinc-plated, corrosion resistant |
Compatibility
This output flange is designed for the ZF WG 65 Series transmission family, which includes models such as the WG65, WG80, WG120, WG150, WG180, and WG200. It is also compatible with select ZF Ecomat and Ecolife variants that share the same output shaft spline geometry. Always verify the spline count and pilot diameter against your specific transmission model before ordering. For complete assembly, consider pairing this flange with the 0631306085: CYLINDRICAL PIN for alignment and the 0634313118: O-RING for sealing.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616105413 | OUTPUT | Transmits torque from gearset to flange |
| 4616101117 | TRANSMISSION HOUSING | Encloses and supports internal components |
| 0636011038 | HEXAGON SCREW | Secures flange to output shaft |
| 0636016015 | HEXAGON SCREW | Fastens housing to transmission case |
| 0631306085 | CYLINDRICAL PIN | Aligns flange during installation |
| 0634313118 | O-RING | Prevents oil leakage at flange joint |
| 0732611049 | FILTER INSERT | Cleans transmission hydraulic fluid |
| 0634303718 | O-RING | Seals filter housing connection |
| 0636610082 | STUD | Provides threaded mounting point |
| 4616301221 | TUBE | Routes oil to cooler system |
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