Overview
The ZF 4657.085.003 5 WG 230 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the main gear cluster, clutch packs, and hydraulic control components into a single, ready-to-install package. As the core power delivery module for the WG 230 series, it replaces the entire rotating assembly within the transmission housing. The SKU 4657.085.003 is the direct OEM reference for this complete unit, ensuring precise fitment and load capacity for graders, loaders, and industrial vehicles.
Symptoms of Failure
- Erratic shifting or gear slipping under load: Worn clutch discs or damaged seals within the assembly cause the transmission to slip during acceleration or when climbing grades, often accompanied by a burning smell.
- Delayed engagement when shifting from Neutral to Drive: A failing power shift unit may take several seconds to engage, indicating internal hydraulic pressure loss or worn piston rings.
- Metallic grinding or whining noise from the transmission center: Bearing failure or gear tooth damage inside the assembly produces a distinct noise that increases with engine RPM, signaling imminent catastrophic failure.
- External oil leaks near the bell housing or rear seal area: Cracks in the TRANSMISSION HOUSING or worn gaskets allow transmission fluid to escape, leading to low pressure and overheating.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number / SKU | 4657.085.003 |
| Assembly Type | 5-Speed Powershift (Complete Unit) |
| 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 |
| OEM Reference | ZF 4657.085.003 |
| Torque Capacity (max) | 2,300 Nm |
| Input Spline Count | 14-tooth (SAE C) |
Compatibility
This complete unit is specifically engineered for the ZF WG 230 Series powershift transmissions. It is directly compatible with models including the WG180, WG200, and WG230 found in Volvo, Case, and New Holland heavy equipment. The assembly interfaces with the HOUS.FRONT SECT and the HOUSING REAR PART to form the complete transmission case. For specific vehicle applications, always verify the serial number against the HOUSING REAR SECTION to ensure correct oil gallery alignment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural case enclosing the gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing the input shaft and pump drive |
| 4657201170 | HOUSING REAR PART | Rear section supporting output shaft bearings |
| 4657298102 | HOUSING REAR SECTION | Extended rear housing for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | M16 bolt for securing housing halves |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump pickup |
| 0636100803 | CAP SCREW | M12 bolt for valve body attachment |
