Overview
The ZF 4697.202.004 SHIM is a precision-engineered OEM genuine part designed to establish critical axial clearances within ZF construction machinery transmissions. This shim sits between the transmission housing and bearing assemblies, ensuring that gear stacks and shafts maintain their exact end-play tolerances under heavy load. By compensating for manufacturing tolerances and wear, the SKU 4697.202.004 prevents metal-to-metal contact and maintains optimal gear mesh alignment. This component is frequently replaced during a full transmission rebuild alongside the 4699101153 HOUSING and the 4699301250 HOUSING to restore factory-specified clearances.
Symptoms of Failure
- Excessive gear backlash and clunking during shifting: When the shim wears or compresses beyond specification, axial play increases, causing a noticeable “clunk” when engaging forward or reverse gears in wheel loaders and excavators.
- Premature bearing failure and whining noise: A worn shim allows the bearing race to walk on its shaft, generating a high-pitched whine that intensifies with engine RPM. This is a common symptom in ZF WG transmissions operating under high torque.
- Oil contamination from metal debris: As the shim disintegrates, fine metallic particles circulate through the hydraulic system, often clogging the filter and causing erratic clutch engagement. This failure mode is frequently misdiagnosed as a pump issue.
- Transmission overheating due to increased friction: Incorrect shim thickness alters gear contact patterns, generating excess heat that degrades transmission fluid and accelerates seal failure around the 4699309121 HOUSING COVER.
Technical Specifications
| Specification | Value |
|---|---|
| Part Number / SKU | 4697.202.004 |
| Material | Case-hardened steel (DIN 1.7131) |
| Thickness | 0.50 mm (0.0197 in) |
| Outer Diameter | 62.0 mm (2.44 in) |
| Inner Diameter | 42.0 mm (1.65 in) |
| Weight | 0.015 kg (0.033 lb) |
| OEM Reference | ZF 4697.202.004 |
| Surface Finish | Ground, Ra ≤ 0.8 µm |
Compatibility
This shim is engineered for ZF WG series powershift transmissions commonly used in construction machinery. It is a direct fit for the following models: WG180, WG200, WG210, WG211, and WG310. The part is also compatible with select ZF ERGOPOWER transmissions used in telescopic handlers and forklifts. Always verify the shim stack height during installation; if the clearance exceeds 0.10 mm, combine this shim with a 0636101411 CAP SCREW torqued to 45 Nm to secure the housing assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4699101153 | HOUSING | Main transmission casing; houses gear sets and shafts |
| 4699301250 | HOUSING | Intermediate housing for clutch pack assembly |
| 4699309121 | HOUSING COVER | Seals the rear of the transmission; contains oil passages |
| 0636101411 | CAP SCREW | M10x35 hex bolt for housing flange retention |
| 0631302072 | CYLINDRICAL PIN | Dowel pin for precise housing alignment |
| 0636302013 | SCREW PLUG | G1/4″ plug for oil drain port |
| 0501331653 | SCREW PLUG | M18x1.5 plug for pressure test port |
| 0634801038 | SEALING RING | Copper washer for plug sealing |
| 0637885613 | BREATHER | Vent valve for pressure equalization |
| 0769100082 | TYPE PLATE | Identification plate with transmission serial number |
