Overview
The ZF 5840.302.059 CLUTCH CAPSULE is a critical hydraulic actuation component engineered for the WG100, WG130, and WG131 transmission series. This OEM genuine part functions as the primary pressure-sealing unit within the clutch pack assembly, converting hydraulic pilot pressure into precise mechanical force for gear engagement. Located directly on the transmission valve body, the SKU 5840.302.059 ensures consistent clutch modulation and prevents cross-contamination between oil circuits. When paired with a properly maintained 2098109042 DIFFERENTIAL, this capsule maintains the hydraulic integrity required for smooth power transfer in heavy-duty industrial applications.
Symptoms of Failure
- Erratic gear engagement or delayed shifting – A worn clutch capsule causes inconsistent hydraulic pressure, leading to harsh or delayed clutch pack engagement during acceleration.
- Internal transmission oil leaks – Cracks or seal degradation in the 5840.302.059 allow ATF to bypass the clutch piston, visible as puddling near the bell housing or valve body.
- Clutch slip under load – When the capsule fails to hold pressure, the clutch pack slips during uphill climbs or heavy towing, generating excessive heat and burnt oil smell.
- Erratic neutral-to-drive transitions – A failing capsule produces a momentary delay or “clunk” when shifting from neutral to drive, especially in cold operating temperatures.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 5840.302.059 |
| OEM Reference | ZF 5840.302.059 |
| Material | Hardened steel body with nitrile rubber seals |
| Outer Diameter | 42 mm |
| Length | 68 mm |
| Weight | 0.185 kg |
| Operating Pressure | 8–12 bar |
| Temperature Range | -30°C to +120°C |
Compatibility
This clutch capsule is specifically designed for ZF WG-series transmissions. Verified compatible models include WG100, WG130, and WG131. It also fits select variants of the WG180 and WG200 series when used with the correct valve body adapter. For differential-side components, always verify fitment with the 2098309011 CROWN WHEEL and the 2099209001 DIFFERENTIAL assembly. The capsule interfaces directly with the 2098309010 DIFFERENTIAL HOUSING in certain integrated axle configurations.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 2098109042 | DIFFERENTIAL | Distributes torque to axle shafts |
| 2098309011 | CROWN WHEEL | Transfers final drive power |
| 2099209001 | DIFFERENTIAL | Secondary differential assembly |
| 2098309010 | DIFFERENTIAL HOUSING | Encloses differential gears |
| 2098309009 | DIFFERENTIAL HOUSING | Alternate housing variant |
| 2098309031 | AXLE BEVEL GEAR | Drives axle shaft rotation |
| 2098309030 | AXLE BEVEL GEAR | Matching bevel gear set |
| 2098309032 | DIFFERENTIAL BEVEL GEAR | Internal differential gear |
| 12883200682 | THRUST WASHER | Reduces axial friction |
| 0635332059 | BALL BEARING | Supports rotating shafts |
