Overview
The ZF 4616.308.138 SPUR GEAR is a critical power transmission component engineered specifically for the WG 65 Series transmission family. This OEM genuine part functions as a precision-machined gear that transfers rotational force between parallel shafts within the transmission’s auxiliary drive or countershaft assembly. Designed to exacting ZF tolerances, the 4616.308.138 spur gear ensures smooth, efficient torque delivery and minimal backlash during operation. It is commonly installed in conjunction with the 4616101059 TRANSMISSION HOUSING, which provides the structural enclosure and bearing support for this gear. The spur gear’s straight-cut teeth engage with mating gears to maintain consistent speed ratios under heavy loads, making it indispensable for reliable transmission performance in industrial and commercial vehicle applications.
Symptoms of Failure
When the ZF 4616.308.138 spur gear begins to wear or fail, operators may notice several distinct symptoms that indicate immediate attention is required. Whining or grinding noise during gear engagement is a common early warning sign, often caused by pitting or chipping on the gear teeth surfaces. Vibration or shuddering under load can occur when uneven wear disrupts the gear mesh, leading to increased stress on adjacent components like the 0636011038 HEXAGON SCREW fasteners. Metal particles in the transmission oil are a definitive indicator of spur gear degradation, as fragments from worn teeth contaminate the lubricant. Intermittent slipping or loss of power transfer may also develop, particularly when the gear’s tooth profile becomes excessively worn, reducing contact area and torque capacity. Addressing these failure symptoms promptly can prevent cascading damage to the transmission housing and associated hardware.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number / SKU | 4616.308.138 |
| Gear Type | Spur Gear, Straight Cut |
| Material | Case-Hardened Alloy Steel (20MnCr5 equivalent) |
| Outside Diameter | Approx. 138 mm |
| Face Width | 32 mm |
| Bore Diameter | 45 mm |
| Number of Teeth | 28 |
| Weight | 1.85 kg (4.08 lbs) |
| OEM Reference | ZF 4616.308.138 |
| Hardness | 58-62 HRC (case depth 0.8-1.2 mm) |
Compatibility
This ZF 4616.308.138 spur gear is designed for use in the WG 65 Series transmission family, which includes models such as the WG65, WG80, WG100, WG120, WG150, WG180, and WG200. It is a direct replacement for the original equipment gear found in the countershaft or auxiliary drive assembly of these transmissions. When replacing this gear, it is essential to also inspect and replace associated sealing and fastening components. The 0636011118 HEXAGON SCREW and 0636016015 HEXAGON SCREW are commonly used to secure the gear hub or retaining plates during installation. Always verify transmission serial number and configuration to ensure correct fitment, as minor variations exist between WG65 sub-series.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4616101059 | TRANSMISSION HOUSING | Encloses and supports the spur gear assembly |
| 0636011038 | HEXAGON SCREW | Secures gear retaining components |
| 0636011118 | HEXAGON SCREW | Fastens gear hub to shaft |
| 0636016015 | HEXAGON SCREW | Mounting bolt for gear cover |
| 0631306085 | CYLINDRICAL PIN | Aligns gear to shaft keyway |
| 0634313118 | O-RING | Seals gear shaft bore |
| 0636304019 | SCREW PLUG | Closes oil passage ports |
| 0634801152 | SEALING RING | Prevents oil leakage at gear hub |
| 0732611049 | FILTER INSERT | Filters oil for gear lubrication |
| 0634303718 | O-RING | Seals transmission housing joint |
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