ZF 4651.004.024 4 WG 100(500) Powershift Transmission Assembly | Complete Unit

Overview

The ZF 4651.004.024 4 WG 100(500) Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway machinery. As the core hydraulic-mechanical assembly in the WG 100 series, this unit integrates the torque converter, clutch packs, and planetary gear sets into a single, pre-assembled module. The SKU 4651.004.024 is the direct replacement for the original 4 WG 100(500) configuration, ensuring precise oil flow paths and gear engagement. This assembly sits between the engine flywheel housing and the output driveline, managing power distribution under extreme load. For a full rebuild, pair this unit with a new 4651101007: TRANSMISSION HOUSING to guarantee structural integrity and alignment.

Symptoms of Failure

• Delayed or harsh engagement when shifting from neutral to forward – Worn clutch piston seals inside the assembly cause pressure loss, leading to a “clunk” or hesitation. This is a common search query for “ZF WG100 shifting delay fix.”
• Internal oil leaks pooling under the bell housing – Degraded O-rings and gaskets within the 4651.004.024 allow ATF to escape, often misdiagnosed as a simple pan leak. Search for “ZF powershift transmission oil leak from housing.”
• Loss of power under load with no visible external damage – Slipping clutch packs due to worn friction discs reduce torque transfer, especially in reverse. This matches queries like “ZF transmission slipping in reverse WG100.”
• Metallic grinding noise during gear changes – Bearing failure inside the assembly creates debris that contaminates the hydraulic system. This symptom often leads to searches for “ZF transmission grinding noise repair kit.”

Technical Specifications

Compatibility

This complete unit is engineered for the ZF WG 100 series, specifically the 4-speed WG100(500) variant. It is directly compatible with models using the 500 Nm torque rating, including the WG100, WG101, and early WG120 configurations. While the WG180 and WG200 series share similar hydraulic architecture, they require different clutch pack counts and output shafts. Always verify your transmission’s serial number against the 4651.004.024 prefix. For housing repairs on related models, the 4651301029: HOUSING and 4651301024: HOUSING are common replacements for the WG180 series.

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