Overview
The ZF 4657.023.003 3 WG 190 Powershift Transmission Assembly is a complete, factory-sealed unit designed for heavy-duty off-highway machinery. This core assembly integrates the main gear cluster, clutch packs, and hydraulic control valving into a single drop-in replacement module. As the central power transfer component in the WG 190 series, it converts engine torque into precisely controlled wheel speed and direction. The SKU 4657.023.003 represents the fully assembled transmission, ready for installation after removing the worn unit. This assembly sits between the torque converter and the final drive, managing all forward and reverse gear ratios under load.
Symptoms of Failure
- Delayed or harsh gear engagement: When the internal clutch packs or sprags wear, operators experience a noticeable lag or a violent “clunk” when shifting between forward and reverse under load.
- Progressive loss of hydraulic pressure: Worn seals or scored valve bodies cause the transmission to slip under heavy load, often accompanied by a whining noise from the pump circuit.
- External oil leaks at the main case seam: Fatigue cracks or gasket failure in the TRANSMISSION HOUSING or the HOUS.FRONT SECT allow transmission fluid to escape, leading to low oil levels and eventual overheating.
- Intermittent neutral condition: A failing planetary gear set or a broken CYLINDRICAL PIN inside the drum can cause the transmission to suddenly drop out of gear, creating a safety hazard on inclines.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight (dry) | ~185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Primary Material | Cast iron housing with steel alloy gears |
| OEM Reference | ZF 4657.023.003 |
| Max Input Torque | 1,900 Nm |
| Number of Speeds | 3 forward / 3 reverse (powershift) |
| Hydraulic Pressure Range | 18–22 bar |
Compatibility
This complete unit is engineered for the ZF WG 190 series. It is directly compatible with the WG 190, WG 191, and WG 192 models used in wheel loaders, forklifts, and telehandlers. While the WG 180 and WG 200 series share similar architecture, the 4657.023.003 assembly is specifically calibrated for the 190-class torque converter and final drive ratios. Always verify the serial number on your existing HOUSING REAR PART to confirm fitment before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101033 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201027 | HOUS.FRONT SECT | Front section housing torque converter |
| 4657201012 | HOUSING REAR PART | Rear section supporting output shaft |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0636100801 | CAP SCREW | Fastener for housing bolts |
| 4656301148 | FIXING PLATE | Retains clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for oil pump |
| 0636100803 | CAP SCREW | Fastener for valve body cover |
| 4681301040 | OIL FEED.HOUSG. | Pressurized oil supply manifold |
Frequently Asked Questions
Q: Can I install this 4657.023.003 assembly without replacing the torque converter?
A: It is strongly recommended to replace the torque converter simultaneously. Worn converter bushings can contaminate the new transmission with debris, leading to premature failure of the clutch packs.
Q: Does this unit include the valve body and solenoids?
A: Yes, the complete assembly includes the hydraulic valve body, shift solenoids, and internal wiring harness. Only external filters and cooler lines need to be connected.
Q: What is the typical service life of this WG 190 assembly in a wheel loader?
A: With proper maintenance and clean oil, the unit typically lasts 8,000–10,000 operating hours before requiring a rebuild. Harsh applications like rock handling may reduce this interval.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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