Overview
This complete ZF 4656.054.112 4 WG 160 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway machinery. As the core power distribution module in the WG 160 series, it manages torque conversion and gear selection under extreme loads. The SKU 4656.054.112 represents a factory-matched assembly that includes the main gear cluster, clutch packs, and hydraulic control system. When rebuilding a transmission, this unit works in concert with the 4656101031: TRANSMISSION HOUSING to ensure precise alignment of all rotating components. The assembly also integrates with the 4656201075: HOUS.FRONT SECT and the 4656201036: HOUSING REAR PART to form a sealed, pressurized oil circuit.
Symptoms of Failure
- Erratic gear engagement under load: When the internal clutch packs wear, operators report delayed or harsh shifting, especially when moving from forward to reverse. This is a common “ZF powershift slipping” issue.
- Torque converter shudder at low RPM: A worn stator or damaged one-way clutch causes vibration during inching operations, often misdiagnosed as engine trouble.
- External oil seepage from bell housing: Degraded seals in the pump drive area allow ATF to pool near the flywheel, creating a “transmission oil leak at front” scenario.
- Loss of hydraulic pressure in cold starts: Internal wear in the valve body or pump reduces flow, leading to “no movement in cold weather” complaints.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight (dry) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 410 mm |
| Overall Height | 380 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| OEM Reference | ZF 4656.054.112 |
| Max Input Torque | 1,600 Nm |
| Oil Capacity (system) | 22 liters |
| Bolt Torque (housing) | 120 Nm (M12 bolts) |
Compatibility
This complete unit is engineered for the ZF WG 160 series, but its core architecture is shared across several models. It directly fits WG 160, WG 180, and WG 200 transmissions used in wheel loaders, forklifts, and telehandlers. The assembly also adapts to older WG 150 and WG 120 variants when paired with the correct 4472239179: HOUSING REAR PART. For applications requiring a different bell housing pattern, the front section can be swapped using the 4656201075: HOUS.FRONT SECT.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4656101031 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4656201075 | HOUS.FRONT SECT | Front bell housing for torque converter |
| 4656201036 | HOUSING REAR PART | Rear cover with PTO mount |
| 4472239179 | HOUSING REAR PART | Alternate rear housing for WG 180 |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing halves |
| 4656301148 | FIXING PLATE | Retains clutch piston assembly |
| 0636100817 | CAP SCREW | M12 bolt for housing fastening |
| 4656301016 | SCREEN SHEET | Fine mesh oil filter (short) |
| 4656301017 | SCREEN SHEET | Fine mesh oil filter (long) |
| 0636100803 | CAP SCREW | M10 bolt for valve body |
Frequently Asked Questions
Q: Can this assembly be installed without removing the torque converter?
A: No. The 4656.054.112 unit requires the torque converter to be detached first. Always inspect the converter hub for wear before reassembly.
Q: What oil type is recommended for this WG 160 unit?
A: Use ZF TE-ML 03 or 05 approved fluids (e.g., Shell Spirax S4 ATF). Do not use standard Dexron III as it may cause clutch chatter.
Q: Does this part include the valve body or is it sold separately?
A: This is a complete assembly that includes the main valve body. However, the solenoid harness and speed sensors are not included and must be ordered separately.
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Phone: +86 158 2286 3467 |
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