Overview
The ZF 4657.203.002 OUTPUT FLANGE is a critical driveline component engineered for the WG160, WG190, and WG210 series transmissions. This OEM genuine part serves as the mechanical interface between the transmission output shaft and the driveshaft, transferring rotational torque from the gearset to the vehicle’s wheels. Positioned at the rear of the transmission assembly, the output flange is splined to the output shaft and sealed against the TRANSMISSION HOUSING to prevent fluid loss. The SKU 4657.203.002 is manufactured to ZF’s exacting tolerances, ensuring a precise fit and long service life in heavy-duty commercial applications.
Symptoms of Failure
When the ZF 4657.203.002 output flange begins to wear, operators may notice these specific failure indicators:
- Transmission fluid leaks at the rear seal: A worn flange surface or damaged sealing lip allows oil to escape, often visible as drips beneath the bell housing.
- Driveline vibration during acceleration: Excessive spline wear or flange runout causes imbalance, transmitting harsh vibrations through the chassis at highway speeds.
- Clunking noise when shifting gears: Loose fit between the flange and output shaft creates audible play, particularly during load changes or gear engagement.
- Premature bearing or seal failure: A distorted flange can misalign the output shaft, accelerating wear on the HOUS.FRONT SECT and adjacent bearings.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number (SKU) | 4657.203.002 |
| Material | Forged steel, induction-hardened |
| Overall Diameter | 180 mm (approx.) |
| Overall Length | 95 mm (approx.) |
| Spline Count | 24 (internal) |
| Weight | 3.2 kg (approx.) |
| OEM Reference | ZF 4657.203.002 |
| Torque Capacity | 2,100 Nm (max) |
Compatibility
This output flange is specifically designed for the ZF WG160, WG190, and WG210 transmission families. It is also compatible with the closely related WG180 and WG200 models, which share the same output shaft spline geometry and bolt pattern. The 4657.203.002 flange interfaces directly with the HOUSING REAR PART (part number 4656201035) and the HOUSING REAR PART (part number 4472239178) in certain WG210 variants. Always verify the transmission serial number before ordering to ensure correct fitment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4656101037 | TRANSMISSION HOUSING | Main structural casing that encloses the gearset and supports the output flange |
| 4656201075 | HOUS.FRONT SECT | Front section of the transmission housing, mates to the bell housing |
| 4656201035 | HOUSING REAR PART | Rear housing section that contains the output shaft bearing and seal |
| 4472239178 | HOUSING REAR PART | Alternate rear housing variant for WG210 series transmissions |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for precise positioning of housing sections during assembly |
| 4656301148 | FIXING PLATE | Retains the output flange and prevents axial movement on the shaft |
| 0636100817 | CAP SCREW | High-strength fastener used to secure the fixing plate to the output shaft |
| 4656301016 | SCREEN SHEET | Filter screen for the transmission oil pump intake |
| 4656301017 | SCREEN SHEET | Alternative filter screen variant for specific oil pan configurations |
| 0636100803 | CAP SCREW | Fastener for securing the rear housing to the main transmission casing |
Frequently Asked Questions
Q: How do I know if the 4657.203.002 output flange is compatible with my WG190 transmission?
A: This flange is a direct OEM replacement for all WG160, WG190, and WG210 series transmissions. Check the spline count (24 internal splines) and the bolt pattern on your existing flange. If your transmission has a 180mm diameter flange face, this part will fit.
Q: Can I reuse the old seal when installing a new output flange?
A: No. Always replace the rear oil seal when installing a new output flange. A worn seal will leak against the fresh flange surface, causing premature failure. We recommend ordering a new seal and the FIXING PLATE (4656301148) for a complete repair.
Q: What torque specification should I use for the output flange retaining nut?
A: The retaining nut should be torqued to 450 Nm (332 ft-lb) for WG160 and WG190 models, and 500 Nm (369 ft-lb) for WG210 models. Always use a new CAP SCREW (0636100817) and apply thread-locking compound to prevent loosening.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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