Overview
The ZF 4661.004.035 4 WG 94 Powershift Transmission Assembly | Complete Unit is a fully integrated drop-in assembly designed for heavy-duty off-highway applications. This complete unit serves as the central power distribution hub within the WG 94 series, managing torque flow and gear selection under high-stress conditions. The SKU 4661.004.035 denotes a factory-matched assembly that includes the main gear cluster, clutch packs, and hydraulic control components. It sits directly between the engine bell housing and the output driveline, requiring precise alignment with the TRANSMISSION HOUSING and the HOUSING II to maintain structural integrity under load.
Symptoms of Failure
- Delayed or harsh engagement — When the assembly wears internally, operators report a noticeable lag between shifting and power delivery, often accompanied by a clunking sound.
- Erratic gear slipping under load — A worn unit may cause the transmission to momentarily lose drive torque on inclines or during heavy pulling, leading to unsafe operating conditions.
- Contaminated transmission fluid with metallic debris — Internal component degradation produces fine metal particles in the oil, visible during routine fluid changes or filter inspections.
- External oil seepage from the main joint — Cracks or gasket failure in the assembly can cause fluid to weep around the mating surface with the CYLINDRICAL PIN alignment points.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4661.004.035 |
| Assembly Type | Complete Powershift Unit (4 WG 94) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 410 mm |
| Primary Material | Cast Iron Housing with Hardened Steel Gears |
| OEM Reference | ZF 4661.004.035 |
| Torque Capacity (est.) | 900 Nm (664 lb-ft) |
| Fluid Capacity (est.) | 8.5 liters |
Compatibility
This complete unit is engineered for the ZF WG 94 series of powershift transmissions. It is directly compatible with models including the WG180, WG200, and WG211 variants commonly found in telehandlers, wheel loaders, and industrial tractors. The assembly also interfaces with the TUBE for hydraulic fluid routing, ensuring proper lubrication to all clutch packs. Always verify your transmission serial number against the WG 94 family before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101028 | TRANSMISSION HOUSING | Encloses the gear train and supports bearing alignment |
| 4661301049 | HOUSING II | Secondary casing section for clutch pack retention |
| 4661301093 | TUBE | Hydraulic fluid conduit between pump and valve body |
| 0631306174 | CYLINDRICAL PIN | Precision alignment dowel for housing mating |
| 0769123894 | TYPE PLATE | Identification tag with serial number and specs |
| 0750100022 | SCREW PLUG | Seals fluid drain or test ports |
| 0636302602 | SCREW PLUG | Secondary port sealing plug |
| 0634100633 | O-RING | Hydraulic seal for plug and tube connections |
| 4661301029 | NOZZLE | Oil jet for gear lubrication |
| 4661301027 | NOZZLE | Secondary oil jet for clutch cooling |
