ZF 4657.024.152 4 WG 190 Powershift Transmission Assembly | Complete Unit

Overview

This complete ZF 4657.024.152 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core power distribution module in the WG 190 series, it manages torque conversion and gear selection under extreme loads. The SKU 4657.024.152 replaces worn or failed assemblies, restoring machine performance in wheel loaders, dozers, and graders. This unit sits between the engine flywheel and the driveline, housing all planetary gearsets, clutches, and hydraulic controls. For a complete rebuild, ensure the TRANSMISSION HOUSING is inspected alongside this assembly.

Symptoms of Failure

• Delayed or harsh engagement: When the transmission hesitates before moving or slams into gear, the internal clutch packs or valve body may be failing. This is a common sign that the 4657.024.152 assembly requires replacement.
• Oil leaks at housing seams: External fluid loss around the HOUS.FRONT SECT or HOUSING REAR PART indicates gasket or seal degradation, often requiring a full unit swap.
• Gear slipping under load: A sudden loss of power during uphill travel or heavy digging suggests worn friction discs or a damaged torque converter within the assembly.
• Unusual whining or grinding noises: Metallic sounds from the transmission bellhousing point to bearing failure or debris contamination, necessitating immediate replacement of the complete unit.

Technical Specifications

Compatibility

This 4657.024.152 assembly is engineered for the ZF WG 190 series, specifically the 4 WG 190 variant. It is also compatible with the WG 180 and WG 200 series transmissions when used as a direct replacement for the complete unit. The assembly fits ZF models installed in Caterpillar, Volvo, and Komatsu heavy equipment from the 1990s through early 2010s. Always verify the bellhousing pattern and output flange configuration against your existing unit before installation.

Related Components

Frequently Asked Questions

Q: Can this 4657.024.152 assembly be rebuilt instead of replaced?
A: While individual components like seals and clutches can be serviced, the complete unit is often replaced to avoid hidden wear in the housing or valve body. For a full overhaul, order the TRANSMISSION HOUSING separately if the original is damaged.

Q: What is the typical lifespan of this WG 190 transmission assembly?
A: Under normal operating conditions with regular fluid changes, the 4 WG 190 unit lasts 8,000 to 12,000 hours. Symptoms like slipping or leaks indicate it is time to replace the 4657.024.152 assembly.

Q: Does this unit include the torque converter?
A: Yes, the complete assembly includes the integrated torque converter. For additional mounting hardware, check the HOUS.FRONT SECT for any needed gaskets or seals.