Overview
The ZF 4661.042.007 2 WG 94 Powershift Transmission Assembly | Complete Unit is a fully assembled, ready-to-install gearbox core designed for heavy-duty off-highway machinery. This complete unit integrates the main gear cluster, clutch packs, and hydraulic control elements within a single robust housing. As the central power transfer module in the WG 94 series, it converts engine torque into controlled, multi-speed output for wheel loaders, dozers, and graders. The SKU 4661.042.007 identifies this as a factory-matched assembly, ensuring precise alignment of internal components such as the TRANSMISSION HOUSING and the HOUSING II, which together form the structural backbone of the unit.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or degraded seals inside the assembly cause delayed shifts or loss of torque during operation, often accompanied by a burning smell.
- External oil leaks at housing seams: Cracks or fatigue in the main casing or the HOUSING II allow transmission fluid to escape, leading to low pressure and eventual overheating.
- Unusual grinding or whining noises: Bearing wear or gear tooth damage within the 2 WG 94 assembly produces metallic sounds that intensify with speed changes.
- Intermittent loss of forward or reverse: Hydraulic valve sticking or a damaged CYLINDRICAL PIN can prevent proper clutch pack engagement, leaving the machine immobile.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4661.042.007 |
| Assembly Type | Complete Powershift Unit (2 WG 94) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| OEM Reference | ZF 4661.042.007 |
| Seal Type | Viton® O-rings and PTFE lip seals |
Compatibility
This complete unit is engineered for the ZF WG 94 series of powershift transmissions, which includes models such as the WG180, WG200, and WG220. These transmissions are commonly found in articulated dump trucks, wheel loaders, and industrial tractors from manufacturers like Volvo, Liebherr, and Caterpillar. The assembly directly replaces the original unit in 4-speed and 6-speed configurations, provided the vehicle uses the 2 WG 94 variant. Always verify the TYPE PLATE on your existing transmission to confirm model compatibility before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101024 | TRANSMISSION HOUSING | Main structural casing for gear and clutch support |
| 4661301054 | HOUSING II | Secondary housing covering the output shaft section |
| 0631306174 | CYLINDRICAL PIN | Alignment dowel for precise housing mating |
| 0769123894 | TYPE PLATE | Identification tag with transmission serial and model |
| 0750100022 | SCREW PLUG | Seals oil drain or fill ports |
| 4660201008 | SCREW PLUG | High-pressure port plug for hydraulic circuits |
| 0636100117 | SCREW PLUG | Magnetic plug for debris collection in sump |
| 0501211384 | VALVE | Modulates clutch apply pressure |
| 0732042156 | COMPRESSION SPRING | Returns valve spool to neutral position |
| 0768409154 | SCREW PLUG | Hex socket plug for cooler line ports |
