Overview
The ZF 4661.002.016 4 WG 90 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This fully assembled gearbox integrates the clutch packs, planetary gearsets, and hydraulic control system into a single, ready-to-install package. As the core of the WG 90 Series drivetrain, the SKU 4661.002.016 replaces the entire transmission assembly, eliminating the need for piecemeal repairs. It sits directly between the engine bellhousing and the final drive, managing torque distribution across four forward and reverse speeds. When installing this assembly, ensure the 4661101032: TRANSMISSION HOUSING is properly aligned to support the main shaft, and verify the 4661301047: HOUSING II is free of cracks to maintain oil pressure integrity.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or piston seals inside the assembly cause delayed shifts or complete loss of drive in specific ranges.
- External oil leaks near the bellhousing or output flange: Degraded gaskets or a cracked 4661301093: TUBE can allow ATF to escape, leading to low pressure and overheating.
- Metallic grinding noise during directional changes: Failed bearings or damaged planetary gears produce a distinct whine or grind, often accompanied by vibration in the shift lever.
- Hydraulic pressure fluctuations: A failing control valve or blocked oil passage results in inconsistent clutch application, causing the machine to lurch or stall.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4661.002.016 |
| Assembly Type | 4 WG 90 Powershift Transmission |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 560 mm |
| Housing Material | High-strength cast iron |
| Clutch Disc Material | Sintered bronze on steel |
| Max Input Torque | 900 Nm (664 lb-ft) |
| Fluid Capacity | 12.5 liters (3.3 gal) |
| OEM Reference | ZF 4 WG 90 |
Compatibility
This complete unit is engineered for the ZF WG 90 Series, which includes the WG90, WG180, and WG200 transmission models commonly found in telescopic handlers, wheel loaders, and agricultural tractors. It directly replaces the 4-speed powershift variant used in machines from manufacturers such as JCB, Manitou, and Claas. The assembly is also compatible with earlier WG 80 Series housings when paired with the correct 0631306174: CYLINDRICAL PIN for alignment. Always cross-reference your existing transmission tag before ordering; the 0769123894: TYPE PLATE provides the definitive model code.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101032 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4661301047 | HOUSING II | Secondary housing for clutch pack and valve body |
| 4661301093 | TUBE | Oil delivery conduit between pump and clutch |
| 0631306174 | CYLINDRICAL PIN | Precision alignment dowel for housing mating |
| 0769123894 | TYPE PLATE | Identification tag with serial and model number |
| 0750100022 | SCREW PLUG | Seals oil fill and drain ports |
| 0636302602 | SCREW PLUG | Magnetic plug for ferrous debris capture |
| 0634100633 | O-RING | Hydraulic seal for plug and tube connections |
| 4661301041 | NOZZLE | Oil jet for planetary gear lubrication |
| 4661301062 | NOZZLE | Secondary oil jet for clutch pack cooling |
