ZF 4657.024.147 4 WG 190 Powershift Transmission Assembly | Complete Unit

Overview

This ZF 4657.024.147 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched 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 clutch packs into a single sealed assembly. The SKU 4657.024.147 replaces worn or failed assemblies to restore full hydraulic shift control and load-holding capability in wheel loaders, dozers, and material handlers. This unit interfaces directly with the TRANSMISSION HOUSING to form the main structural backbone of the drivetrain.

Symptoms of Failure

• Delayed or harsh engagement – When the internal clutch packs wear, operators experience a noticeable lag between shifting and power delivery, often accompanied by a jarring engagement.
• Internal oil leaks and low pressure – Worn seals within the assembly cause transmission fluid to bypass the clutches, leading to erratic shift timing and visible drips from the bell housing area.
• Gear slipping under load – As the unit loses hydraulic integrity, the transmission slips out of gear when pushing heavy loads, especially in forward-reverse cycles.
• Unusual whining or grinding noises – Bearing wear or planetary gear damage inside the assembly produces a high-pitched whine or metallic grinding during operation.

Technical Specifications

Compatibility

This complete assembly is engineered for the ZF WG 190 series transmissions. It is a direct fit for models including the WG 180, WG 190, and WG 200, which are commonly used in articulated dump trucks, wheel loaders, and graders. The unit is designed to bolt directly to the HOUS.FRONT SECT and HOUSING REAR PART without modification. For complete rear sealing, the HOUSING REAR SECTION is also required to finalize the assembly.

Related Components

Frequently Asked Questions

Q: Can the 4657.024.147 assembly be rebuilt, or is it a sealed unit?
A: This is a complete, sealed assembly designed for direct replacement. While internal components like clutch packs can be serviced, ZF recommends replacing the entire unit to ensure proper hydraulic balance and avoid cascading failures.

Q: What transmission fluid is recommended for this WG 190 assembly?
A: Use ZF TE-ML 03 or TE-ML 05 approved fluids (SAE 10W or 15W-40). Always check the dipstick after installation, as the new assembly requires a specific fill volume of approximately 22 liters.

Q: Does this unit include the torque converter?
A: Yes, the 4657.024.147 ships as a complete powershift assembly with the torque converter, pump drive, and all internal clutches pre-installed. You only need to attach the external housings and fasteners.