Overview
This complete ZF 4657.024.040 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As a core component of the WG 190 series, this assembly manages torque distribution across four forward and reverse speeds, ensuring smooth clutch engagement under load. The SKU 4657.024.040 represents a factory-matched assembly that includes the main gear train, clutch packs, and hydraulic control elements. It sits directly between the engine flywheel housing and the final drive, acting as the primary power modulation interface. For structural integrity, this unit integrates with the TRANSMISSION HOUSING which provides the rigid backbone for all rotating components.
Symptoms of Failure
- Delayed engagement or gear slipping under load: When the internal clutch packs or hydraulic seals degrade, operators notice hesitation when shifting from neutral to forward or reverse, particularly on inclines.
- External oil leaks near the bell housing: Worn gaskets or cracked casings cause transmission fluid to seep from the joint between the HOUS.FRONT SECT and the main body, leading to low fluid levels and overheating.
- Abnormal whining or grinding noises: Bearing fatigue or gear tooth pitting produces a high-pitched metallic sound that intensifies with engine RPM, indicating imminent internal failure.
- Erratic shift patterns or loss of power: A failing valve body or blocked oil passages cause the transmission to skip gears or fail to hold torque, often accompanied by a burning clutch smell.
Technical Specifications
| Parameter | Value |
|---|---|
| Overall Length | 620 mm |
| Dry Weight | 195 kg |
| Housing Material | Cast Iron (GGG-40) |
| OEM Reference | ZF 4657.024.040 |
| Max Input Torque | 1,200 Nm |
| Oil Capacity | 18.5 Liters |
Compatibility
This complete assembly is specifically engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 190, WG 191, and WG 192 models used in wheel loaders, telehandlers, and industrial tractors. The unit also shares mounting patterns with the WG 180 series when paired with the appropriate HOUSING REAR PART. For WG 200 series applications, additional adapter plates may be required. The assembly uses a CYLINDRICAL PIN for precise alignment during installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201027 | HOUS.FRONT SECT | Front section housing input shaft |
| 4657201020 | HOUSING REAR PART | Rear casing for output shaft support |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0636100801 | CAP SCREW | Fastener for housing joints |
| 4656301148 | FIXING PLATE | Retainer for clutch pack alignment |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump |
| 0636100803 | CAP SCREW | Bolt for valve body mounting |
| 4681301040 | OIL FEED.HOUSG. | Lubrication channel housing |
Frequently Asked Questions
Q: Can the ZF 4657.024.040 be rebuilt rather than replaced?
A: Yes, this assembly can be rebuilt using individual clutch packs and seals. However, if the TRANSMISSION HOUSING shows cracks or wear, a complete unit replacement is recommended for reliability.
Q: What oil type is recommended for this WG 190 assembly?
A: ZF specifies a high-quality SAE 10W-30 or SAE 15W-40 engine oil meeting ZF TE-ML 03C or 07F standards. Always verify the oil level after installing the HOUS.FRONT SECT to ensure proper lubrication.
Q: How do I verify the alignment of the CYLINDRICAL PIN during installation?
A: Insert the pin into the dowel hole on the HOUSING REAR PART before torquing the cap screws. The pin should slide in freely without force; any resistance indicates misalignment of the housing sections.
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Phone: +86 158 2286 3467 |
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