Overview
The ZF 4656.054.068 4 WG 160 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the main gear set, clutch packs, and hydraulic control system into a single, ready-to-install package. As the core power transfer component in the WG 160 series, it replaces the entire rotating assembly and valve body. The SKU 4656.054.068 is the definitive reference for this complete unit, ensuring you receive the exact OEM-specification assembly without the need for core exchange or partial rebuilds.
Symptoms of Failure
- Erratic shifting or gear slipping under load: Worn clutch discs or degraded seals inside the assembly cause the transmission to lose hydraulic pressure, resulting in delayed engagement or complete loss of drive in specific ranges.
- Internal hydraulic leaks and low oil pressure: Cracks in the TRANSMISSION HOUSING or wear in the HOUS.FRONT SECT allow pressurized oil to bypass, leading to overheating and sluggish performance.
- Metal debris in the oil filter or pan: Advanced wear of planetary gears or thrust washers generates metallic contamination, often accompanied by a whining noise from the HOUSING REAR PART area.
- Complete loss of forward or reverse: A seized bearing or fractured shaft within the assembly can cause sudden, catastrophic failure, leaving the vehicle immobile.
Technical Specifications
| Parameter | Specification |
|---|---|
| Assembly Type | Complete Powershift Unit (4 WG 160) |
| OEM Reference | ZF 4656.054.068 |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Housing Material | High-Grade Aluminum Alloy |
| Max Input Torque | 1,600 Nm |
| Number of Speeds | 4 Forward / 4 Reverse |
| Mounting Interface | SAE 3 (Bellhousing) |
Compatibility
This complete unit is specifically engineered for the ZF WG 160 series. It is also compatible with the WG 180 and WG 200 series transmissions when used with the appropriate HOUSING REAR PART adapter. Common applications include ZF 4WG-160, 4WG-180, and 4WG-200 models found in telescopic handlers, wheel loaders, and industrial tractors. Always verify your transmission serial number against the SKU 4656.054.068 before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4656101031 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4656201075 | HOUS.FRONT SECT | Front section housing pump and PTO drive |
| 4656201036 | HOUSING REAR PART | Rear casing supporting output shaft |
| 4472239179 | HOUSING REAR PART | Alternate rear housing for WG 180/200 |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 4656301148 | FIXING PLATE | Secures clutch pack retaining ring |
| 0636100817 | CAP SCREW | M12 bolt for housing flange |
| 4656301016 | SCREEN SHEET | Fine mesh filter for oil sump |
| 4656301017 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | M10 bolt for valve body mounting |
Frequently Asked Questions
Q: Does the 4656.054.068 assembly include the torque converter?
A: No, this is the complete powershift assembly only. The torque converter and bellhousing are separate components. You will need to transfer your existing converter or order a new one separately.
Q: Can I install this unit in a ZF WG 200 transmission?
A: Yes, with modification. You must use the 4472239179 rear housing adapter to match the longer output shaft of the WG 200 series. All internal clutch packs and gears are identical.
Q: What is the typical lifespan of this complete assembly?
A: In normal industrial use with proper maintenance (clean oil and filter changes every 500 hours), the assembly typically lasts 8,000–10,000 operating hours before requiring a rebuild.
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Phone: +86 158 2286 3467 |
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