Overview
The ZF 4657.024.031 4 WG 190 Powershift Transmission Assembly | Complete Unit is a fully assembled, ready-to-install core component designed for heavy-duty off-highway applications. This complete unit integrates the clutch packs, planetary gear sets, and hydraulic control system into a single, pre-tested assembly. As a direct replacement for the WG 190 series, the SKU 4657.024.031 ensures precise fitment and restores original ZF performance. It sits at the heart of the driveline, transferring engine torque to the output shaft through four forward and reverse powershift speeds. For a full rebuild, this assembly must be paired with a robust TRANSMISSION HOUSING to protect internal components from debris and stress.
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, especially when maneuvering heavy loads.
- Internal hydraulic pressure loss: Cracks in the valve body or piston bores lead to low line pressure, resulting in sluggish response and overheating.
- Metallic debris in oil filter: Bearing or gear wear generates fine metal particles, indicating imminent failure of the complete unit.
- Audible whining or grinding from the bell housing: Damaged planetary gears or thrust washers produce distinct noise during acceleration or deceleration.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4657.024.031 |
| Series | WG 190 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-strength cast iron |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Input Torque Capacity | Up to 1,900 Nm |
| Fluid Capacity | 22 liters (ZF TE-ML 03) |
| OEM Reference | ZF 4657.024.031 |
Compatibility
This complete unit is engineered specifically for the ZF WG 190 series. It is also compatible with the WG 180 and WG 200 transmission families when used with the correct adapter kit. The assembly integrates directly with the HOUS.FRONT SECT and the HOUSING REAR PART to form a sealed driveline. Always verify the bell housing pattern and output flange configuration before installation. The unit also requires the CYLINDRICAL PIN for precise alignment during assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Encloses and protects internal gears and clutches |
| 4657201027 | HOUS.FRONT SECT | Front section housing for input shaft and pump |
| 4657201020 | HOUSING REAR PART | Rear section housing for output shaft and PTO |
| 0631306792 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | Fastener for housing joints |
| 4656301148 | FIXING PLATE | Secures clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | High-torque fastener for valve body |
| 4681301040 | OIL FEED.HOUSG. | Distributes pressurized oil to clutch packs |
Frequently Asked Questions
Q: Is the ZF 4657.024.031 a direct bolt-in replacement for a WG 190?
A: Yes, this complete unit is a factory-spec assembly designed for direct installation into WG 190 transmissions. Ensure the mating housing and front section are free of damage before mounting.
Q: What oil type is recommended for this assembly?
A: ZF recommends TE-ML 03 specification oil (SAE 10W-30 or 15W-40 depending on ambient temperature). Always replace the SCREEN SHEET filters during installation.
Q: Can this unit be rebuilt, or must it be replaced entirely?
A: While individual clutch packs and seals can be serviced, the complete unit is typically replaced as a whole to avoid hidden wear in the planetary carriers. We recommend using a new CYLINDRICAL PIN and FIXING PLATE with every replacement.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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