Overview
This complete ZF 4657.024.046 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core drivetrain component in the WG 190 series, it manages torque distribution across four forward and reverse speeds. The assembly includes the main gear cluster, clutch packs, and hydraulic control system. When sourcing a replacement, ensure you reference the SKU 4657.024.046 for exact fitment. This unit works in concert with the TRANSMISSION HOUSING to protect internal components from debris and thermal stress.
Symptoms of Failure
- Delayed or harsh gear engagement: Worn clutch packs or hydraulic pressure loss cause hesitation when shifting from neutral to drive, often accompanied by a loud clunk.
- Torque converter shudder under load: A vibrating sensation during acceleration at low RPM indicates internal wear in the stator or turbine assembly.
- External oil leaks near the bell housing: Degraded seals allow transmission fluid to escape, leaving puddles under the vehicle and reducing hydraulic pressure.
- Intermittent loss of power in forward gears: Slipping clutches prevent full torque transfer, causing the engine to rev without proportional vehicle movement.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Reference | ZF 4657.024.046 |
| Assembly Weight | Approx. 185 kg (408 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 480 mm |
| Housing Material | Cast iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| Fluid Capacity | 22 liters |
Compatibility
This assembly is engineered for the ZF WG 190 series, but it also fits select models in the WG 180 and WG 200 families when paired with the correct HOUS.FRONT SECT and HOUSING REAR PART. It is commonly used in ZF 4 WG 190, 4 WG 180, and 4 WG 200 transmissions found in telescopic handlers, wheel loaders, and industrial tractors. Always verify the bell housing pattern and output flange configuration before installation. The CYLINDRICAL PIN is required for precise alignment during assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101031 | TRANSMISSION HOUSING | Encloses and protects internal gear sets |
| 4657201027 | HOUS.FRONT SECT | Front section of the main housing |
| 4657201020 | HOUSING REAR PART | Rear section of the main housing |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0636100801 | CAP SCREW | Fastener for housing sections |
| 4656301148 | FIXING PLATE | Secures internal components |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | Bolt for valve body attachment |
| 4681301040 | OIL FEED.HOUSG. | Distributes hydraulic fluid to clutches |
Frequently Asked Questions
Q: Can this 4 WG 190 assembly be rebuilt, or must it be replaced as a unit?
A: While individual clutch packs and seals can be replaced, the 4657.024.046 is typically sold as a complete unit to ensure all internal clearances and hydraulic circuits are matched. For partial repairs, the TRANSMISSION HOUSING and HOUS.FRONT SECT are available separately.
Q: What is the typical service life of this transmission assembly?
A: With proper maintenance and clean fluid, the ZF 4 WG 190 can exceed 8,000 operating hours. Early failure is often linked to contaminated oil or worn CYLINDRICAL PIN alignment causing housing misalignment.
Q: Does this unit include the torque converter?
A: No, the 4657.024.046 is the transmission assembly only. The torque converter is a separate component. Ensure you also inspect the HOUSING REAR PART for cracks if replacing the unit.
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Phone: +86 158 2286 3467 |
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