Overview
The ZF 4661.042.005 2 WG 94 Powershift Transmission Assembly is a complete, factory-spec unit designed for heavy-duty off-highway applications. This assembly serves as the central power transfer module within the WG 94 series, managing clutch engagement and torque distribution under extreme loads. The SKU 4661.042.005 identifies a fully assembled transmission that integrates the main gear set, hydraulic control system, and output shaft. It mounts directly to the engine bell housing and connects to the driveline through the rear output flange. For proper sealing and structural integrity, this unit requires the 4661101024: TRANSMISSION HOUSING and the 4661301054: HOUSING II to enclose the rotating components.
Symptoms of Failure
- Delayed or harsh gear engagement – When the internal clutch packs or hydraulic seals degrade, operators experience a noticeable lag or jarring shift between forward and reverse ranges.
- Oil leaks at the housing seams – Worn gaskets or cracked casings cause transmission fluid to seep from the joint between the main housing and the rear cover, often visible as drips under the vehicle.
- Loss of power under load – Internal wear on the planetary gears or torque converter stator leads to slipping, reducing tractive effort when climbing grades or pushing material.
- Unusual whining or grinding noises – Damaged bearings or gear teeth produce a high-pitched whine during acceleration or a grinding sound during deceleration, indicating imminent failure.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4661.042.005 |
| Assembly Type | Complete Powershift Transmission |
| Series | WG 94 |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 820 mm |
| Overall Width | 510 mm |
| Overall Height | 590 mm |
| Housing Material | Cast Iron (GGG-40) |
| OEM Reference | ZF 4661.042.005 |
| Fastener Torque (housing bolts) | 120 Nm |
| Fluid Capacity | 22 L (SAE 10W-30) |
Compatibility
This complete unit is engineered for the ZF WG 94 series of powershift transmissions. Based on its design and part number structure, it is compatible with the following ZF models: WG180, WG200, and WG240. These transmissions are commonly found in articulated dump trucks, wheel loaders, and graders from manufacturers such as Volvo, Caterpillar, and Case. The assembly includes the 0631306174: CYLINDRICAL PIN for precise alignment of the clutch packs, and the 0769123894: TYPE PLATE for identification. Always verify your transmission serial number before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101024 | TRANSMISSION HOUSING | Main structural casing that supports gears and shafts |
| 4661301054 | HOUSING II | Rear cover housing for output shaft and bearings |
| 0631306174 | CYLINDRICAL PIN | Alignment dowel for clutch pack assembly |
| 0769123894 | TYPE PLATE | Identification tag with serial number |
| 0750100022 | SCREW PLUG | Oil drain plug for transmission pan |
| 4660201008 | SCREW PLUG | Fill port plug for hydraulic circuit |
| 0636100117 | SCREW PLUG | Pressure test port plug |
| 0501211384 | VALVE | Modulating valve for clutch pressure control |
| 0732042156 | COMPRESSION SPRING | Return spring for shift valve spool |
| 0768409154 | SCREW PLUG | Sealing plug for cooler line port |
