Overview
This ZF 4657.024.029 4 WG 190 Powershift Transmission Assembly is a complete, ready-to-install unit designed for heavy-duty industrial and agricultural machinery. As the core hydraulic-mechanical power transfer module, it integrates the clutch packs, planetary gear sets, and valve body into a single sealed assembly. The SKU 4657.024.029 is a direct OEM replacement for the WG 190 series, ensuring precise gear engagement under high torque loads. It sits centrally within the drivetrain, connecting the engine output to the final drive via the TRANSMISSION HOUSING and the HOUS.FRONT SECT.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or degraded seals inside the assembly cause delayed shifts or loss of torque transfer, especially when operating on inclines.
- Hydraulic fluid leaks near the bell housing: Cracks in the HOUSING REAR PART or damaged O-rings allow pressurized oil to escape, leading to low system pressure and overheating.
- Metallic grinding or whining noise during operation: Failed bearings or damaged planetary gears produce audible debris, often accompanied by vibration through the chassis.
- Transmission fails to hold park or neutral: A broken CYLINDRICAL PIN or shift fork misalignment prevents the unit from locking into position.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.024.029 |
| Series | WG 190 (4 WG 190) |
| Type | Powershift Transmission Assembly (Complete Unit) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-grade cast iron (GGG-40) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| OEM Reference | ZF 4657.024.029 |
| Input Spline Count | 14-tooth, 2.5 module |
| Max Input Torque | 1,200 Nm |
Compatibility
This complete unit is engineered for the ZF WG 190 series, including the WG 180, WG 190, and WG 200 variants used in telehandlers, wheel loaders, and forestry equipment. It is also backward-compatible with select 4-speed powershift models from the WG 170 series when paired with the correct TRANSMISSION HOUSING. Always verify the bell housing pattern and output flange dimensions against your existing unit before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101045 | TRANSMISSION HOUSING | Main structural casing that encloses the gear train and oil sump. |
| 4657201027 | HOUS.FRONT SECT | Front section housing the input shaft and torque converter interface. |
| 4657201020 | HOUSING REAR PART | Rear casing that supports the output shaft and PTO drive. |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for precise housing mating during assembly. |
| 0636100801 | CAP SCREW | Fastener for securing the front housing section to the main case. |
| 4656301148 | FIXING PLATE | Locking plate that prevents fastener loosening under vibration. |
| 4657301032 | SCREEN SHEET | Fine mesh filter for the hydraulic suction line (version A). |
| 4657301033 | SCREEN SHEET | Fine mesh filter for the hydraulic return line (version B). |
| 0636100803 | CAP SCREW | Fastener for the rear housing and oil pan attachment. |
| 0750301003 | OIL FEED.HOUSG. | Oil feed housing that directs pressurized fluid to the clutch packs. |
Frequently Asked Questions
Q: Is the ZF 4657.024.029 a direct bolt-in replacement for my WG 190 transmission?
A: Yes, this complete unit is a factory-spec assembly for the WG 190 series. It includes all internal components and requires no modification when replacing an existing 4 WG 190 unit.
Q: What tools are needed to install the CYLINDRICAL PIN (0631306792) during reassembly?
A: A soft-faced mallet and alignment drift are recommended. The pin must be pressed flush into the HOUS.FRONT SECT before mating with the main housing.
Q: Can I reuse the existing SCREEN SHEET (4657301032) with this new assembly?
A: It is strongly advised to replace both screen sheets (4657301032 and 4657301033) during a full transmission overhaul to prevent debris from contaminating the new unit.
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