Overview
The ZF 4657.024.033 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the clutch packs, planetary gearsets, and hydraulic control system into a single, ready-to-install package. As a core component of the WG 190 Series, the SKU 4657.024.033 replaces the entire rotating assembly and valve body, ensuring precise shift timing and torque delivery. It sits directly between the engine bellhousing and the final drive, serving as the central power distribution module for loaders, graders, and industrial tractors.
Symptoms of Failure
- Erratic or delayed gear engagement: When the internal clutch packs or seals degrade, operators experience a noticeable lag when shifting from forward to reverse, often accompanied by a harsh “clunk.”
- Transmission overheating under light load: Worn thrust washers or damaged oil feed passages cause internal leakage, raising sump temperatures above 120°C even during moderate operation.
- Oil contamination with metallic debris: Fractured planetary gear teeth or worn friction discs shed particles into the fluid, visible as glitter in the oil filter or drain plug.
- Intermittent loss of drive in specific ranges: A failing 4 WG 190 assembly may lose power in 2nd or 3rd gear while maintaining function in other ranges, indicating a specific clutch piston seal failure.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.024.033 |
| Series | WG 190 (4-speed Powershift) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| Oil Capacity | 22 liters (SAE 10W-30 or ZF TE-ML 03) |
| Mounting Interface | SAE 3 bellhousing pattern |
Compatibility
This complete unit is engineered for the ZF WG 190 Series, but its internal architecture shares core components with the WG 180 and WG 200 families. Specifically, the 4657.024.033 assembly is a direct fit for models WG 190-I, WG 190-II, and WG 190-III used in Volvo L90/L120 loaders, Case 921E wheel loaders, and John Deere 744K graders. It is not compatible with the WG 150 or WG 210 series without significant adapter modifications. When replacing this unit, always verify the bellhousing bolt pattern and output flange spline count against your original transmission tag.
During installation, the TRANSMISSION HOUSING (4657101031) must be inspected for cracks, as it supports the entire clutch drum assembly. The HOUS.FRONT SECT (4657201027) and HOUSING REAR PART (4657201020) must align perfectly to prevent oil gallery misalignment. Finally, the CYLINDRICAL PIN (0631306792) is critical for dowel alignment during final assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201027 | HOUS.FRONT SECT | Front section housing input shaft and pump drive |
| 4657201020 | HOUSING REAR PART | Rear section supporting output shaft and PTO |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing halves |
| 0636100801 | CAP SCREW | M12 bolt for housing flange fastening |
| 4656301148 | FIXING PLATE | Locks clutch piston retaining ring |
| 4657301032 | SCREEN SHEET | Fine mesh filter for lube circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for suction line |
| 0636100803 | CAP SCREW | M10 bolt for valve body attachment |
| 4681301040 | OIL FEED.HOUSG. | Pressurized oil distribution manifold |
Frequently Asked Questions
Q: Can I install the 4657.024.033 assembly without replacing the torque converter?
A: Yes, but ZF recommends replacing the torque converter stator and lockup clutch simultaneously. The new assembly has tighter clutch clearances, and an old converter can introduce debris that damages the fresh valve body.
Q: What is the typical service life of this complete unit?
A: In wheel loader applications with proper maintenance (50-hour oil changes), the 4 WG 190 assembly typically lasts 8,000–12,000 hours before requiring a rebuild. Harsh environments like mining reduce this to 5,000–7,000 hours.
Q: Does this unit include the shift controller or solenoid harness?
A: No. The 4657.024.033 is the mechanical and hydraulic core only. You must reuse your existing TCU (transmission control unit) or order the separate wiring harness and solenoid kit (part number 4657.024.034).
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Phone: +86 158 2286 3467 |
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