Overview
This complete ZF 4657.024.028 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 190 series, it manages clutch engagement and gear selection under high torque loads. The assembly integrates the main gear sets, valve body, and output shaft within a sealed housing. When replacing a worn unit, the SKU 4657.024.028 ensures a direct fit without modification. This complete assembly eliminates the need to rebuild individual subcomponents, reducing downtime for industrial graders, loaders, and dozers.
Symptoms of Failure
- Delayed or harsh gear engagement: When the internal clutch packs or hydraulic circuits wear, operators experience a noticeable lag or violent shift when moving from neutral to forward or reverse.
- Torque converter overheating: A failing internal seal or worn bearing within the 4657.024.028 assembly can cause fluid bypass, leading to elevated transmission temperatures and eventual thermal degradation.
- Intermittent power loss under load: As internal components fatigue, the transmission may slip or lose drive pressure when the machine is pushing heavy material, often accompanied by a whining noise from the gear train.
- External fluid seepage at housing joints: Cracks or gasket failure in the main casing allow ATF to weep from the bell housing or rear seal area, leaving visible drips on the undercarriage.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.024.028 |
| Assembly Type | Complete Powershift Transmission |
| Series | WG 190 |
| Dry Weight (approx.) | 285 kg (628 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron |
| OEM Reference | ZF 4 WG 190 |
| Torque Capacity | Up to 1,900 Nm |
Compatibility
This complete unit is engineered for the ZF WG 190 series, which includes the WG 180, WG 190, and WG 200 variants. It is commonly installed in construction equipment such as the Volvo G-Series graders, Case 800-series dozers, and Caterpillar 140M motor graders. The 4657.024.028 assembly also fits select models of the ZF 4WG-180 and 4WG-200 transmissions when used with the appropriate adapter plates. Always verify the bell housing pattern and output flange configuration before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Main structural casing that encloses the gear train and valve body. |
| 4657201027 | HOUS.FRONT SECT | Forward section of the housing supporting the torque converter and pump drive. |
| 4657201020 | HOUSING REAR PART | Rear casing segment that houses the output shaft and parking brake assembly. |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel used to precisely locate housing halves during assembly. |
| 0636100801 | CAP SCREW | High-tensile fastener for securing the housing to the engine bell housing. |
| 4656301148 | FIXING PLATE | Retention plate for the clutch piston return springs. |
| 4657301032 | SCREEN SHEET | Fine mesh filter for the main pressure line (inner diameter). |
| 4657301033 | SCREEN SHEET | Fine mesh filter for the main pressure line (outer diameter). |
| 0636100803 | CAP SCREW | Fastener for the rear housing cover plate. |
| 4681301040 | OIL FEED.HOUSG. | Lubrication distribution manifold for the planetary gear sets. |
Frequently Asked Questions
Q: Can the 4657.024.028 assembly be rebuilt, or is it a sealed unit?
A: This is a complete assembly designed for replacement rather than field rebuild. While internal components such as clutch discs and seals can be serviced, the housing and valve body are matched as a set. We recommend replacing the entire unit to ensure proper hydraulic balance and avoid core charge issues.
Q: What is the typical service life of this transmission assembly?
A: In normal construction applications with proper maintenance (filter changes every 500 hours), the 4 WG 190 assembly typically lasts 8,000 to 12,000 operating hours. Severe loading or contaminated fluid can reduce this significantly.
Q: Does this part include the torque converter?
A: Yes, the 4657.024.028 is a complete powershift unit that includes the integrated torque converter, all planetary gear sets, and the hydraulic valve body. It does not include the external oil cooler or remote filter head.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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