Overview
The ZF 4616.303.026 SPUR GEAR is a critical power transmission component engineered specifically for the WG 65 Series transmission assembly. This OEM genuine part, identified by SKU 4616.303.026, functions as a precision-machined gear that transfers rotational force between parallel shafts within the gear train. It sits directly within the intermediate shaft cluster, meshing with adjacent gears to maintain synchronized speed ratios during heavy-duty operation. When paired with a robust TRANSMISSION HOUSING, this spur gear ensures minimal backlash and optimal torque delivery under extreme loads.
Symptoms of Failure
- Whining or grinding noise during gear engagement: Worn gear teeth produce a high-pitched metallic sound, especially under load, indicating surface fatigue or pitting on the 4616.303.026 spur gear.
- Intermittent gear slipping or hesitation: As tooth profiles degrade, the gear loses positive engagement, causing momentary power loss or delayed response when shifting through WG 65 ranges.
- Metallic debris in transmission fluid: Flaking or chipped gear teeth generate visible metal particles in the oil, often detected during routine filter changes or when inspecting the FILTER INSERT.
- Vibration at specific RPM ranges: Uneven wear on the spur gear creates harmonic imbalances, producing noticeable driveline shudder during acceleration or deceleration.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4616.303.026 |
| Gear Type | Spur Gear (Straight Cut) |
| Material | Case-Hardened Alloy Steel (20MnCr5 equivalent) |
| Module | 4.5 mm (estimated) |
| Number of Teeth | 32 (estimated) |
| Outside Diameter | 153 mm (estimated) |
| Face Width | 35 mm (estimated) |
| Weight | 1.85 kg (estimated) |
| OEM Reference | ZF 4616.303.026 |
| Hardness | 58-62 HRC (case depth 0.8-1.2 mm) |
Compatibility
This spur gear is designed for the ZF WG 65 Series transmission family. Based on its tooth geometry and shaft interface, it is also compatible with the following ZF models that share the same intermediate gear cluster architecture: WG 65, WG 80, WG 100, WG 120, WG 150, WG 180, and WG 200. Always verify the gear count and spline fitment against your specific transmission serial number before installation. The gear mounts directly onto the countershaft and requires proper torque specifications using HEXAGON SCREW fasteners (M10 x 1.5) and HEXAGON SCREW (M12 x 1.75) for secure retention. Additional HEXAGON SCREW (M16 x 2.0) hardware is used in the bearing cap assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101059 | TRANSMISSION HOUSING | Encloses and supports the gear train assembly |
| 0636011038 | HEXAGON SCREW | M10 fastener for housing and bearing retention |
| 0636011118 | HEXAGON SCREW | M12 fastener for gear and shaft locking |
| 0636016015 | HEXAGON SCREW | M16 fastener for heavy-duty bearing caps |
| 0631306085 | CYLINDRICAL PIN | Alignment pin for gear-to-shaft positioning |
| 0634313118 | O-RING | Seals housing joint against oil leakage |
| 0636304019 | SCREW PLUG | Closes oil drain or inspection ports |
| 0634801152 | SEALING RING | Prevents fluid bypass at shaft exits |
| 0732611049 | FILTER INSERT | Captures debris from gear wear in oil circuit |
| 0634303718 | O-RING | Secondary seal for filter housing cover |
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