Overview
The ZF 4651.004.046 4 WG 100(500) Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the clutch packs, planetary gearsets, and hydraulic control valves into a single, ready-to-install package. As a core component of the WG 100 Series, it manages torque distribution and speed changes under load. The SKU 4651.004.046 identifies this specific 4-speed configuration with a 500 Nm torque rating, ensuring precise power delivery for wheel loaders, forklifts, and industrial tractors. It sits directly between the engine flywheel and the final drive, replacing the entire rotating assembly within the main TRANSMISSION HOUSING.
Symptoms of Failure
- Delayed engagement or “slipping” under load: When the internal clutch packs wear, the transmission hesitates before moving forward or reverse, especially on inclines. This is a common search query for “ZF powershift slipping when hot.”
- Hydraulic oil leaks at the bell housing: Worn seals or a cracked HOUSING allow ATF to escape, leaving puddles under the vehicle. Search terms like “ZF transmission oil leak between engine and transmission” often point to this assembly.
- Erratic shifting or harsh engagement: A failing valve body or worn clutch plates cause jarring shifts, often accompanied by a “clunk” sound. This matches queries for “ZF powershift hard shifting forward.”
- Loss of power in higher gears: The unit may fail to hold 3rd or 4th gear, forcing the operator to run at lower speeds. This is frequently searched as “ZF WG100 won’t shift into 4th gear.”
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | Cast Iron (GGG-40) |
| Torque Capacity | 500 Nm (369 lb-ft) |
| Number of Speeds | 4 Forward / 4 Reverse |
| OEM Reference | ZF 4651.004.046 |
| Seal Kit Required | O-RING (0634303928) |
Compatibility
This complete unit is engineered for the ZF WG 100 Series transmission family. It is directly compatible with the WG 100(500) variant. Based on its mechanical architecture, it also fits the WG 120 and WG 150 models when used with the appropriate TRANSMISSION HOUSING. It is not recommended for the WG 180 or WG 200 series without verifying bell housing bolt patterns and input shaft spline counts.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4651101014 | TRANSMISSION HOUSING | Main structural casing for the assembly |
| 4651301029 | HOUSING | Rear cover for clutch pack access |
| 0634303928 | O-RING | Seals the housing joint to prevent leaks |
| 4651301036 | TRANSMISSION HOUSING | Front housing for input shaft support |
| 4651203002 | SCREEN SHEET | Filters debris from hydraulic oil |
| 4651303005 | SCREEN SHEET | Secondary filtration for valve body |
| 0636101032 | CAP SCREW | Fastens housing sections together |
| 0630361028 | SEALING CAP | Closes unused hydraulic ports |
| 4475280060 | SCREW PLUG | Seals drain and fill holes |
| 0634303312 | O-RING | Seals the screw plug against leakage |
