ZF 4657.024.102 4 WG 190 Powershift Transmission Assembly | Complete Unit

Overview

This ZF 4657.024.102 4 WG 190 Powershift Transmission Assembly is a complete, factory-engineered unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 190 series, it integrates the torque converter, planetary gear sets, and hydraulic control system into a single, ready-to-install assembly. The SKU 4657.024.102 replaces worn or failed transmissions in wheel loaders, graders, and industrial tractors, restoring full forward/reverse shuttle capability and load-sensing performance. This complete unit eliminates the need for piecemeal rebuilding, ensuring OEM-specified clearances and clutch pack tolerances.

Symptoms of Failure

• Delayed or harsh engagement: When the internal clutch packs and seals degrade, operators experience a noticeable lag or jarring shift when moving from forward to reverse, often accompanied by a loss of power under load.
• Low hydraulic pressure and overheating: Worn internal pump gears or valve body wear cause the transmission to run hot, with pressure readings dropping below 150 psi during operation, leading to premature component damage.
• Oil leaks at housing joints: Cracks or fatigue in the main casing allow ATF to seep from the bell housing or PTO cover, leaving visible puddles and requiring frequent fluid top-offs.
• Gear slipping under load: As friction discs wear thin, the transmission loses torque capacity, causing the machine to creep or lose speed on inclines even with full throttle applied.

Technical Specifications

Compatibility

This complete unit is specifically engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 190 models used in Volvo L120/L150 wheel loaders, Case 921E graders, and Liebherr L556 machines. While the core assembly is unique to the WG 190, its internal components share design lineage with the WG 180 and WG 200 series, though the housing dimensions differ. Always verify the transmission serial number against the SKU 4657.024.102 before installation.

During installation, the complete unit must be mated to a sound TRANSMISSION HOUSING (4657101078) to ensure proper alignment. The front section of the assembly integrates with the HOUS.FRONT SECT (4657201166), while the rear structure relies on the HOUSING REAR PART (4657201168) and the HOUSING REAR SECTION (4657298101) for structural integrity.

Related Components

Frequently Asked Questions

Q: Can this complete unit be installed without removing the engine?
A: Yes, the ZF 4657.024.102 is designed for in-frame replacement. You must disconnect the driveline, hydraulic lines, and bell housing bolts. The unit slides out rearward, but ensure the TRANSMISSION HOUSING is free of debris before mating.

Q: What fluid type does this assembly require?
A: Use ZF TE-ML 03 approved synthetic transmission fluid (e.g., Shell Spirax S4 TXM). The unit holds 28 liters. Do not use Dexron III, as it will cause premature clutch glazing.

Q: Does this part include the torque converter?
A: Yes, the 4657.024.102 is a complete powershift assembly that includes the torque converter, all planetary gear sets, and the hydraulic valve body. Only external components like the HOUS.FRONT SECT and cooler lines need to be transferred from your old unit.