Overview
This ZF 4657.024.032 4 WG 190 Powershift Transmission Assembly is a complete, ready-to-install unit designed for heavy-duty industrial applications. As the core of the WG 190 series, this assembly integrates the main gear set, clutch packs, and hydraulic control system into a single, pre-assembled module. The SKU 4657.024.032 serves as the direct replacement for original equipment transmissions in loaders, dozers, and material handlers. It sits between the torque converter and the final drive, managing power distribution across four forward and reverse speeds. For proper installation, this unit mates with the TRANSMISSION HOUSING to seal the internal components, while the HOUS.FRONT SECT and HOUSING REAR PART provide structural support and alignment.
Symptoms of Failure
- Delayed or harsh shifting: Worn clutch packs inside the assembly cause hesitation between gears or abrupt engagement, often accompanied by a metallic grinding noise during power-on shifts.
- Transmission fluid leaks at the bell housing: Degraded seals around the input shaft allow ATF to escape, leaving puddles under the vehicle and reducing hydraulic pressure.
- Loss of power in forward gears: Internal wear or broken planetary gears result in the transmission slipping under load, especially when climbing grades or pushing heavy material.
- Erratic neutral-to-drive engagement: A failing spool valve or damaged piston within the assembly causes the transmission to lurch or fail to engage when shifting from neutral.
Technical Specifications
| Specification | Value |
|---|---|
| OEM Part Number | 4657.024.032 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 410 mm |
| Housing Material | High-Grade Cast Iron |
| Seal Material | Nitrile Rubber (NBR) |
| Bolt Torque (main housing) | 120 Nm |
| OEM Reference | ZF 4 WG 190 |
Compatibility
This assembly is engineered specifically for the ZF WG 190 series transmissions. It is a direct fit for the 4 WG 190 model, and it is also compatible with the WG 180 and WG 200 variants when used with the appropriate adapters. The unit is commonly found in ZF 4WG-190, 4WG-180, and 4WG-200 powershift systems used in construction equipment such as Volvo L120, Caterpillar 950, and Komatsu WA380 wheel loaders. Always verify your transmission model tag before ordering. The assembly requires the CYLINDRICAL PIN for precise alignment during installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Encloses and protects the gear train |
| 4657201027 | HOUS.FRONT SECT | Front section housing for input shaft support |
| 4657201020 | HOUSING REAR PART | Rear section housing for output shaft alignment |
| 0631306792 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | Fastener for housing sections |
| 4656301148 | FIXING PLATE | Secures internal components in place |
| 4657301032 | SCREEN SHEET | Filter screen for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Secondary filter screen for oil return |
| 0636100803 | CAP SCREW | Bolt for screen sheet retention |
| 4681301040 | OIL FEED.HOUSG. | Distributes oil to clutch packs |
Frequently Asked Questions
Q: Can the 4657.024.032 assembly be rebuilt, or is it a sealed unit?
A: This is a complete, pre-assembled unit that is designed for direct replacement. While internal components can be serviced, ZF recommends replacing the entire assembly to ensure proper clearances and hydraulic integrity.
Q: What is the typical lifespan of this transmission assembly under normal operating conditions?
A: With proper maintenance and regular fluid changes, the 4 WG 190 assembly typically lasts 8,000 to 12,000 hours. Harsh environments or heavy loading may reduce this interval.
Q: Does this part include the torque converter?
A: No, this is the transmission assembly only. The torque converter is a separate component and must be ordered independently if needed.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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