Overview
The ZF 4661.044.019 3 WG 94 Powershift Transmission Assembly | Complete Unit is a fully assembled, drop-in replacement designed for heavy-duty off-highway applications. This complete unit integrates the clutch packs, planetary gearsets, and hydraulic control system into a single, pre-tested assembly. As a core component of the WG 94 series, it manages torque distribution across three forward and three reverse speeds. The SKU 4661.044.019 is specifically engineered to interface with the TRANSMISSION HOUSING and the HOUSING II, ensuring precise alignment and oil flow. This assembly eliminates the need for individual part sourcing and complex rebuilds, providing a direct solution for transmission failure.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or damaged seals within the assembly cause the transmission to hesitate or lose torque when shifting, particularly during high-torque maneuvers.
- Internal hydraulic pressure loss: A failing unit often leads to low system pressure, resulting in delayed shifts or complete loss of drive in specific gear ranges.
- Contaminated transmission fluid with metallic debris: As internal components degrade, fine metal particles circulate through the oil, visible during fluid changes or as a gritty residue on the dipstick.
- Audible grinding or whining from the bell housing: Bearing wear or gear tooth damage inside the assembly produces distinct mechanical noises that worsen with engine RPM.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4661.044.019 |
| Assembly Type | Complete Powershift Unit (3 WG 94) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 410 mm |
| Overall Height | 480 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| OEM Reference | ZF 4661.044.019 |
| Torque Capacity | Up to 2,500 Nm |
| Fluid Type | ZF TE-ML 03 / Dexron III |
Compatibility
This complete unit is designed for the WG 94 Series of ZF powershift transmissions. It is a direct fit for models including the WG180, WG200, and WG210, commonly found in wheel loaders, forklifts, and telescopic handlers. The assembly also integrates with earlier variants of the WG 94 family. For proper installation, ensure the CYLINDRICAL PIN is correctly aligned during mounting, and verify the TYPE PLATE matches your unit’s serial number for exact configuration.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4661101042 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4661301108 | HOUSING II | Secondary housing for clutch pack and valve body |
| 0631306174 | CYLINDRICAL PIN | Alignment dowel for precise housing mating |
| 0769123894 | TYPE PLATE | Identification tag with serial and model data |
| 0750100022 | SCREW PLUG | Seals oil passages and drain ports |
| 4660201008 | SCREW PLUG | High-pressure port sealing plug |
| 0636100117 | SCREW PLUG | Low-pressure circuit plug |
| 0501211384 | VALVE | Hydraulic control valve for shift modulation |
| 0732042156 | COMPRESSION SPRING | Returns valve spool to neutral position |
| 0768409154 | SCREW PLUG | Secondary drain plug for housing |
