Overview
The ZF 5840.303.409 OUTER CLUTCH DISK is a critical friction component engineered for the WG100, WG130, and WG131 transmission series. This OEM genuine part sits within the clutch pack assembly, where it manages torque transfer between rotating shafts during gear shifts. By providing precise frictional engagement, the 5840.303.409 ensures smooth power delivery and protects adjacent drivetrain elements from shock loads. This disk works in concert with the 5838109009: DIFFERENTIAL to distribute torque evenly, while the 0750117075: TAPER ROLLER BEARING supports axial loads during clutch actuation. Replacing a worn outer clutch disk with genuine SKU 5840.303.409 restores shift quality and extends transmission service life.
Symptoms of Failure
- Delayed or harsh gear engagement: When the outer clutch disk wears thin, hydraulic pressure cannot clamp the pack effectively, causing hesitation or abrupt shifts during acceleration.
- Transmission fluid contamination: Friction material shedding from a degraded 5840.303.409 disk turns the oil dark and gritty, often clogging filters and valve bodies.
- Torque converter shudder: A failing disk allows intermittent slip under load, producing a vibration felt through the chassis at highway speeds.
- Burning odor from the transmission: Excessive heat generated by a slipping outer clutch disk breaks down fluid and creates a distinct acrid smell, especially in WG100/WG130 units.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number (SKU) | 5840.303.409 |
| Outer Diameter | 180 mm (estimated) |
| Inner Diameter | 130 mm (estimated) |
| Thickness | 3.5 mm (new) |
| Material | Sintered bronze friction lining on steel core |
| Weight | 0.45 kg (approx.) |
| OEM Reference | ZF 5840.303.409 |
| Friction Coefficient | 0.12 (dynamic, oil-wet) |
Compatibility
This outer clutch disk is precision-machined for ZF WG100, WG130, and WG131 transmissions used in medium-duty trucks, buses, and off-highway equipment. It also fits select WG180 and WG200 variants where the clutch pack diameter matches 180 mm. The 5840.303.409 interfaces directly with the 2093209023: DIFFERENTIAL and the 5838300626: DIFFERENTIAL HOUSING to maintain proper gear alignment. Always verify your transmission model code before ordering, as WG131 units may require a different spline count.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 5838109009 | DIFFERENTIAL | Distributes torque between axles |
| 0750117075 | TAPER ROLLER BEARING | Supports radial and axial loads |
| 2093209023 | DIFFERENTIAL | Secondary torque split unit |
| 5838300626 | DIFFERENTIAL HOUSING | Encloses differential gears |
| 0631329088 | SPRING PIN | Secures clutch pack alignment |
| 5838300811 | THRUST WASHER | Reduces axial friction |
| 5838300721 | AXLE BEVEL GEAR | Transfers power to wheel hubs |
| 5838300633 | AXLE | Rotates with differential output |
| 5838300753 | THRUST WASHER | Controls gear end-play |
| 5838300818 | THRUST WASHER | Prevents metal-to-metal contact |
Frequently Asked Questions
Q: How do I know if the 5840.303.409 outer clutch disk is the correct part for my WG130 transmission?
A: Check the stamped part number on the existing disk or consult your ZF transmission serial number. The 5840.303.409 is designed for 180 mm clutch packs; if your unit uses a 200 mm pack, you will need a different disk.
Q: Can I replace just the outer clutch disk without replacing the entire clutch pack?
A: While possible, ZF recommends replacing all friction disks and steels in the same pack to ensure even wear. Mixing old and new disks often leads to premature failure of the 5838109009: DIFFERENTIAL due to uneven torque distribution.
Q: What torque specification should I use when installing the 5840.303.409?
A: Clutch pack retaining nut torque varies by transmission model. For WG100/WG130 units, the standard is 120 Nm. Always refer to the ZF service manual for your specific serial number to avoid damaging the 0750117075: TAPER ROLLER BEARING.
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ZF 5840.303.409 OUTER CLUTCH DISK – Clutch Disk RFQ Support
PartsZF helps B2B buyers source ZF 5840.303.409 OUTER CLUTCH DISK with fast RFQ support, expert part-number lookup, documentation review, and export coordination. This clutch disk 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 5840.303.409 when sending your RFQ. PartsZF can review dotted, spaced, and compact number formats against the available product and documentation records.
Application Context
- Illustration section: DIFFERENTIAL
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 | 5840.303.409 |
|---|---|
| Normalized SKU | 5840303409 |
| Part name | OUTER CLUTCH DISK |
| Product category | clutch disk |
| 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.
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