Overview
The ZF 4657.024.155 4 WG 190 Powershift Transmission Assembly is a complete, fully assembled unit designed for heavy-duty off-highway machinery. This complete assembly integrates the main gear train, clutch packs, and hydraulic control system into a single, ready-to-install package. As a core component of the WG 190 series, this unit (SKU: 4657.024.155) replaces the need for piecemeal repairs by providing a fully validated assembly. It sits at the heart of the drivetrain, managing power distribution from the engine to the axles. For a full rebuild, this assembly must be paired with a robust TRANSMISSION HOUSING to ensure structural integrity.
Symptoms of Failure
- Erratic gear engagement or slipping: When the internal clutch packs or valve body wear, the transmission may hesitate or fail to hold a gear under load, causing power loss during operation.
- External oil leaks at the main case: Cracks or warping in the main casing can lead to significant hydraulic fluid loss, often visible around the bell housing or PTO ports.
- Delayed or harsh shifting: A failing assembly may produce a hard “clunk” when shifting between forward and reverse, or exhibit a noticeable lag before engaging a gear.
- Overheating and burnt fluid smell: Internal wear generates excessive friction, raising operating temperatures and producing a distinct burnt odor from the transmission fluid.
Technical Specifications
| Specification | Value |
|---|---|
| Part Number | 4657.024.155 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Estimated Weight | 185 kg (408 lbs) |
| Housing Material | High-Grade Cast Iron |
| OEM Reference | ZF 4 WG 190 |
| Max Input Torque | 1,200 Nm (885 lb-ft) |
| Fluid Capacity | Approx. 22 Liters |
Compatibility
This complete assembly is engineered for the ZF WG 190 series transmissions. It is directly compatible with the 4 WG 190 model and can be adapted for use in the WG 180 and WG 200 series with specific housing modifications. The unit is commonly found in agricultural tractors, wheel loaders, and industrial forklifts requiring a 4-speed powershift. For proper installation, ensure the HOUS.FRONT SECT and HOUSING REAR PART are correctly aligned with the main assembly. In some variants, the HOUSING REAR SECTION is also required to complete the drivetrain layout.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for the gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201168 | HOUSING REAR PART | Rear section for output shaft support |
| 4657298101 | HOUSING REAR SECTION | Alternative rear housing for specific models |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | Fastener for housing sections |
| 4656301148 | FIXING PLATE | Secures internal components |
| 4657301032 | SCREEN SHEET | Filter screen for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Secondary filter screen |
| 0636100803 | CAP SCREW | Additional fastener for cover plates |
Frequently Asked Questions
Q: Is the 4657.024.155 a direct bolt-in replacement for a 4 WG 190?
A: Yes, this is a complete assembly that replaces the entire transmission unit. It includes all internal gears and clutches, but you must reuse or replace the external housings like the TRANSMISSION HOUSING if damaged.
Q: What causes the transmission to slip after installing a new assembly?
A: Slipping is often due to incorrect fluid level or a clogged filter. Check the SCREEN SHEET and ensure all CAP SCREW fasteners are torqued to spec to prevent internal leaks.
Q: Can this assembly be used in a ZF WG 180 transmission?
A: With the correct HOUS.FRONT SECT and HOUSING REAR PART, it can be adapted, but verify input shaft spline count for compatibility.
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Phone: +86 158 2286 3467 |
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