Overview
The ZF 4616.302.115 FLANGE is a precision-machined coupling component designed specifically for the WG 65 Series transmission. This OEM genuine part serves as the critical interface between the transmission output shaft and the driveline, ensuring secure torque transfer and rotational alignment. Positioned at the rear of the gearbox housing, the flange connects directly to the 4616105415: OUTPUT assembly, providing a sealed, vibration-resistant joint. The SKU 4616.302.115 is manufactured to ZF’s exacting tolerances, guaranteeing a direct replacement fit without modification.
Symptoms of Failure
- Transmission fluid seepage at the rear seal: A worn or cracked flange often leads to oil weeping around the output shaft, leaving visible drips under the vehicle after parking.
- Driveline vibration during acceleration: When the flange’s mating surface becomes distorted or its splines wear, rotational imbalance causes noticeable shuddering, especially between 30-50 mph.
- Clunking noise when shifting gears: Excessive play between the flange and the 4616303144: OUTPUT FLANGE produces a metallic knock during gear engagement or load changes.
- Premature U-joint or bearing failure: A misaligned flange transfers abnormal stress to downstream components, accelerating wear on driveshaft joints and transmission output bearings.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4616.302.115 |
| Material | High-strength forged steel (DIN 1.7225) |
| Outer Diameter | 165 mm (6.50 in) |
| Bolt Hole Circle | 130 mm (5.12 in) |
| Center Bore Diameter | 45 mm (1.77 in) |
| Weight | 2.8 kg (6.2 lbs) |
| Surface Treatment | Zinc-phosphate coating with oil seal |
| OEM Reference | ZF 4616.302.115 |
Compatibility
This flange is engineered for the ZF WG 65 Series transmission family, including models such as WG65, WG80, WG120, WG150, WG180, and WG200. It is also compatible with select ZF Ecomat 4HP and 5HP series when used with the appropriate 4616101094: TRANSMISSION HOUSING. Always verify spline count and bolt pattern against your existing unit before installation. The flange is secured using 0636011038: HEXAGON SCREW fasteners, which must be torqued to factory specifications.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616105415 | OUTPUT | Transfers rotational force from the gearset to the flange |
| 4616303144 | OUTPUT FLANGE | Secondary coupling for dual-flange configurations |
| 4616101094 | TRANSMISSION HOUSING | Encloses and supports the gear train and output assembly |
| 0636011038 | HEXAGON SCREW | M10 bolt for securing flange to output shaft |
| 0636011118 | HEXAGON SCREW | M12 bolt for housing-to-flange attachment |
| 0636016015 | HEXAGON SCREW | M8 bolt for accessory bracket mounting |
| 0631306085 | CYLINDRICAL PIN | Alignment dowel for precise flange positioning |
| 0634313118 | O-RING | Seals the flange-to-housing interface |
| 0732611049 | FILTER INSERT | Inline filtration for hydraulic control circuit |
| 0634303718 | O-RING | Seals the output shaft bore |
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