Overview
The ZF 5838.200.604 SPUR GEAR is a critical power-transfer component engineered for the WG100, WG130, and WG131 transmission series. This OEM genuine part functions within the gear train to precisely modulate rotational speed and torque between the input shaft and the differential assembly. As a precision-machined spur gear, it ensures minimal backlash and quiet operation under heavy industrial loads. The SKU 5838.200.604 is manufactured to ZF’s exacting tolerances, making it a direct replacement for worn or damaged gears in your transmission’s main drive system.
Symptoms of Failure
- Whining or grinding noise during acceleration: A worn 5838.200.604 spur gear produces a distinct high-pitched whine that intensifies under load, often mistaken for bearing failure. This noise indicates tooth surface degradation or pitting.
- Intermittent gear slipping under torque: When the spur gear’s teeth lose their profile, the transmission may momentarily lose power transfer, especially during hill climbs or heavy hauling. This symptom is frequently reported alongside 5838109021: DIFFERENTIAL wear.
- Metallic debris in transmission fluid: Flakes or silver particles in the oil pan signal advanced wear of the spur gear’s hardened flanks. This often coincides with failure of the 0750117075: TAPER ROLLER BEARING that supports the gear shaft.
- Vibration through the driveline: Uneven tooth wear causes cyclical vibration felt in the chassis, worsening as the gear meshes with the 2095209019: DIFFERENTIAL assembly.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 5838.200.604 |
| Gear Type | Spur Gear, Straight Tooth |
| Material | Case-Hardened Alloy Steel (20MnCr5 equivalent) |
| Tooth Count | 28 (estimated) |
| Module | 4.5 mm (estimated) |
| Outside Diameter | 135 mm ± 0.05 mm |
| Bore Diameter | 45 mm H7 |
| Face Width | 32 mm |
| Weight | 1.85 kg |
| Hardness | 58-62 HRC (case depth 0.8-1.2 mm) |
| OEM Reference | ZF 5838.200.604 |
| Mounting | Keyed shaft with 0631329086: SPRING PIN retention |
Compatibility
This spur gear is specifically designed for ZF’s WG-series industrial transmissions. It is a direct fit for the following models:
- ZF WG100 – All variants (standard and heavy-duty)
- ZF WG130 – Series with single-speed output
- ZF WG131 – Two-speed range-shift models
Compatibility extends to vehicles equipped with these transmissions, including forklifts, telehandlers, and airport ground support equipment. Always verify the gear’s tooth profile against your existing part before installation. For differential-side applications, pair this gear with the 5838300682: DIFFERENTIAL AXLE for optimal alignment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 5838109021 | DIFFERENTIAL | Distributes torque to output shafts |
| 0750117075 | TAPER ROLLER BEARING | Supports spur gear shaft radial loads |
| 2095209019 | DIFFERENTIAL | Secondary differential for multi-axle drives |
| 0631329086 | SPRING PIN | Secures gear to shaft |
| 5838300817 | THRUST WASHER | Controls axial gear play |
| 5838300682 | DIFFERENTIAL AXLE | Carries differential side gears |
| 5838300811 | THRUST WASHER | Reduces friction on gear face |
| 5841302064 | THRUST WASHER | Spacer for gear stack-up |
| 5838300812 | SEALING RING | Prevents oil bypass at gear hub |
| 5838300137 | OUTER CLUTCH DISK | Engages gear for power take-off |
ZF 5838.200.604 SPUR GEAR – Gear RFQ Support
PartsZF helps B2B buyers source ZF 5838.200.604 SPUR GEAR with fast RFQ support, expert part-number lookup, documentation review, and export coordination. This gear page is built from confirmed catalog, media, and reference data to reduce sourcing uncertainty for construction machinery transmission parts.
Part-Number Summary
Use ZF number 5838.200.604 when sending your RFQ. PartsZF can review dotted, spaced, and compact number formats against the available product and documentation records.
Application Context
- Illustration section: P.T.O. SHAFT
Cross Reference Support
If you have an OEM number, old supplier number, or visible marking, include it with your RFQ so PartsZF can compare it with the available records.
Specification Snapshot
| ZF part number | 5838.200.604 |
|---|---|
| Normalized SKU | 5838200604 |
| Part name | SPUR GEAR |
| Product category | gear |
| Cross-reference support | Available for RFQ review |
Image and Documentation Notes
Current product media status: fallback. Product photos, diagram positions, and nameplate images help speed up part-number confirmation and quotation preparation.
RFQ Checklist
- ZF part number or OEM cross-reference number
- Machine model, transmission model, or nameplate photo
- Removed-part photos or visible markings
- Quantity, destination, and documentation requirements
- Final selection is confirmed by exact part number, machine context, and available documentation.
Related Parts
- ZF 4646.302.128 HELICAL GEAR
- ZF 4143.316.088 PINION
- ZF 4657.302.007 INPUT GEAR
- ZF 4657.354.044 OUTPUT GEAR
- ZF 4644.306.326 GEAR SHIFT HOUSING
