Overview
This ZF 4657.024.039 4 WG 190 Powershift Transmission Assembly is a complete, ready-to-install unit engineered for heavy-duty industrial applications. As the core assembly for the WG 190 series, it integrates the main gear cluster, clutch packs, and hydraulic control components into a single, precision-machined package. The SKU 4657.024.039 is a direct replacement for OEM configurations, ensuring seamless integration with existing drivelines. It sits at the heart of the powertrain, managing torque distribution and gear selection under extreme loads. For proper installation, this unit mates directly with the TRANSMISSION HOUSING, which provides structural support and fluid containment.
Symptoms of Failure
- Erratic shifting or gear slippage under load: Worn clutch discs or valve body degradation within the assembly cause delayed engagement or complete loss of drive in specific ranges.
- External oil leaks at housing seams: Cracks or gasket failures in the main casing allow hydraulic fluid to escape, often visible as drips near the HOUS.FRONT SECT or rear seal areas.
- Unusual grinding or whining noises: Bearing fatigue or gear tooth pitting inside the assembly generates metallic sounds that intensify with engine RPM.
- Overheating transmission fluid: Internal debris or clutch pack slippage generates excessive heat, triggering warning lights or burnt odor from the dipstick.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4657.024.039 |
| Assembly Type | 4 WG 190 Powershift Transmission (Complete Unit) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| OEM Reference | ZF 4657.024.039 / 4 WG 190 |
| Mounting Hardware | Includes CAP SCREW kit (M16 x 1.5) |
Compatibility
This complete unit is specifically designed for the ZF WG 190 series powershift transmissions. It is directly compatible with the WG 190, WG 191, and WG 192 models commonly found in agricultural tractors, wheel loaders, and industrial forklifts. While primarily for the WG 190, it may also fit select WG 180 and WG 200 variants with minor adapter modifications. The assembly interfaces with the HOUSING REAR PART to complete the main casing structure, and uses a CYLINDRICAL PIN for precise alignment during assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201027 | HOUS.FRONT SECT | Front section housing for input shaft and PTO |
| 4657201020 | HOUSING REAR PART | Rear casing section for output shaft support |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing sections |
| 0636100801 | CAP SCREW | Fastener for housing bolts (M16) |
| 4656301148 | FIXING PLATE | Retainer plate for clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for oil sump |
| 0636100803 | CAP SCREW | Fastener for valve body mounting (M12) |
| 4681301040 | OIL FEED.HOUSG. | Lubrication oil distribution manifold |
Frequently Asked Questions
Q: Is the ZF 4657.024.039 a direct bolt-in replacement for my WG 190 transmission?
A: Yes, this complete unit is a factory-spec assembly designed for direct replacement. Ensure your existing TRANSMISSION HOUSING and front/rear sections are compatible; minor seal replacement may be needed.
Q: What causes the “slipping” symptom in this assembly?
A: Slipping typically results from worn clutch discs or degraded seals inside the unit. It can also be caused by a blocked SCREEN SHEET restricting hydraulic pressure.
Q: Does this assembly include the mounting hardware?
A: The unit ships with the main housing bolts (CAP SCREW set) and alignment pins. Additional fasteners like the CAP SCREW for valve covers are sold separately.
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