Overview
The ZF 4661.004.002 4 WG 94 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway machinery. This assembly integrates the main gear cluster, clutch packs, and hydraulic control components into a single, ready-to-install package. As a core element of the WG 94 Series, it manages torque distribution across four forward and reverse speeds. The SKU 4661.004.002 replaces worn or failed assemblies, restoring full driveline performance in loaders, graders, and industrial tractors. When installing this unit, ensure the TRANSMISSION HOUSING is free of cracks and that the HOUSING mating surfaces are clean to prevent misalignment.
Symptoms of Failure
- Delayed engagement or gear slipping under load: Worn clutch discs or degraded seals inside the assembly cause power loss during acceleration or uphill operation.
- Erratic shifting or harsh engagement: Accumulated debris or valve bore wear disrupts hydraulic pressure, leading to jarring shifts between forward and reverse.
- External oil leaks near the bell housing: Cracks in the assembly casing or failed gaskets allow transmission fluid to escape, often visible as drips after shutdown.
- Unusual whining or grinding noises: Bearing fatigue or gear tooth damage within the unit produces metallic sounds that intensify with engine RPM.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4661.004.002 |
| Assembly Type | Complete Powershift Unit (4 WG 94) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-grade cast iron (GGG-40) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Max Input Torque | 1,200 Nm |
| Oil Capacity | 18 liters (ZF TE-ML 03 fluid) |
| Related Components | TYPE PLATE, SCREW PLUG, SCREW PLUG, O-RING, NOZZLE, NOZZLE |
Compatibility
This complete assembly is engineered for the ZF WG 94 Series, which includes the WG180, WG200, and WG240 transmission models commonly found in construction and agricultural equipment. It is a direct fit for machines originally equipped with the 4 WG 94 variant, such as certain Liebherr, Case, and Volvo loaders. The unit also shares mounting patterns with earlier WG 92 and WG 86 series, though hydraulic line routing may differ. For proper installation, verify that the TUBE for oil supply is unobstructed and that the CYLINDRICAL PIN aligns correctly with the dowel holes in the bell housing.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101006 | TRANSMISSION HOUSING | Encloses and supports gear train and clutch packs |
| 4661301012 | HOUSING | Provides mounting surface for valve body and sensors |
| 4661301093 | TUBE | Routes pressurized oil to clutch packs |
| 0631306174 | CYLINDRICAL PIN | Aligns housing halves during assembly |
| 0769123894 | TYPE PLATE | Identifies transmission model and serial number |
| 0750100022 | SCREW PLUG | Seals oil drain and fill ports |
| 0636302602 | SCREW PLUG | Closes pressure test ports |
| 0634100633 | O-RING | Prevents fluid leaks at plug interfaces |
| 4661301029 | NOZZLE | Sprays lubricant onto planetary gears |
| 4661301027 | NOZZLE | Directs oil to clutch cooling channels |
