Overview
This complete ZF 4657.024.045 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core drivetrain component, it manages torque distribution across four forward and reverse speeds, ensuring smooth power delivery under extreme loads. The SKU 4657.024.045 represents a direct OEM replacement for the WG 190 series, integrating the main gear cluster, clutch packs, and hydraulic control system into a single ready-to-install assembly. This unit sits between the engine flywheel and the final drive, converting rotational power into controlled vehicle motion. For a full rebuild, the TRANSMISSION HOUSING provides the structural foundation, while the HOUS.FRONT SECT and HOUSING REAR PART enclose the rotating elements.
Symptoms of Failure
- Erratic gear engagement or slipping under load — Worn clutch discs or degraded seals inside the 4657.024.045 assembly cause delayed shifts or complete loss of drive, especially when climbing grades.
- Hydraulic oil leaks from bell housing area — Cracks in the TRANSMISSION HOUSING or failed gaskets allow pressurized ATF to escape, leaving puddles under the vehicle.
- Whining or grinding noises during gear changes — Bearing fatigue or misaligned shafts within the assembly produce metallic sounds, indicating imminent internal damage.
- Overheating transmission fluid — Clogged oil passages or a failing torque converter cause the unit to run hot, triggering warning lights on the dashboard.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.024.045 |
| Series | WG 190 |
| Dry Weight | Approx. 195 kg (430 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | Cast iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| Fluid Capacity | 22 liters |
| Mounting Bolt Torque | 120 Nm (M12 bolts) |
Compatibility
This complete unit is engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 180, WG 190, and WG 200 models used in wheel loaders, forklifts, and telehandlers from manufacturers such as Caterpillar, Volvo, and JCB. The assembly also fits select WG 170 variants with adapter modifications. For precise fitment, verify the bell housing pattern against your existing HOUS.FRONT SECT and rear mounting flange.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201027 | HOUS.FRONT SECT | Front section enclosing clutch packs |
| 4657201020 | HOUSING REAR PART | Rear housing supporting output shaft |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0636100801 | CAP SCREW | M12 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Locks bearing in position |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | M10 bolt for valve body attachment |
| 4681301040 | OIL FEED.HOUSG. | Pressurized oil distribution manifold |
Frequently Asked Questions
Q: Can the 4657.024.045 assembly be rebuilt, or must it be replaced as a complete unit?
A: While internal components like clutch discs and seals are serviceable, the complete unit is often replaced due to housing wear. Always inspect the TRANSMISSION HOUSING for cracks before attempting a rebuild.
Q: What is the typical lifespan of this WG 190 transmission assembly?
A: With proper maintenance and clean fluid, the 4657.024.045 typically lasts 8,000–12,000 operating hours. Early failure is often caused by debris entering through the SCREEN SHEET if it becomes damaged.
Q: Does this unit include the torque converter?
A: No, the 4657.024.045 is the transmission assembly only. The torque converter is a separate component that mounts to the HOUS.FRONT SECT using the CYLINDRICAL PIN for alignment.
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