Overview
This complete ZF 4657.024.048 4 WG 190 Powershift Transmission Assembly is a fully integrated drop-in unit designed for heavy-duty off-highway machinery. As the core power transfer module in the WG 190 series, this assembly manages torque distribution across four forward and reverse speeds, enabling precise shuttle shifting under load. The SKU 4657.024.048 represents a factory-matched unit that includes the main gear cluster, clutch packs, and hydraulic control elements. It sits between the engine bell housing and the final drive, converting engine power into controlled tractive effort for wheel loaders, dozers, and graders. This complete assembly eliminates the need for piecemeal rebuilding, offering a direct replacement for worn or failed transmissions in demanding construction and mining environments.
Symptoms of Failure
- Delayed or harsh engagement when shifting between forward and reverse: Worn clutch discs or degraded seals within the 4657.024.048 assembly cause hesitation or abrupt lurching during directional changes, often accompanied by a momentary loss of power.
- Persistent oil leaks around the transmission housing seams: Cracks or gasket failures in the TRANSMISSION HOUSING or HOUS.FRONT SECT allow hydraulic fluid to escape, leading to low pressure and eventual gear slippage.
- Grinding or whining noise during acceleration under load: Worn bearings or damaged planetary gears inside the assembly produce metallic sounds, indicating imminent internal failure that can seize the drivetrain.
- Intermittent loss of drive in specific gear ranges: Hydraulic valve body wear or broken CYLINDRICAL PIN components prevent proper clutch pack engagement, causing the machine to stop moving in one or more gears.
Technical Specifications
| Specification | Value |
|---|---|
| Assembly Weight (Dry) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 480 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| Input Torque Capacity | 1,900 Nm (1,401 lb-ft) |
| OEM Reference | ZF 4657.024.048 |
| Hydraulic Pressure Range | 18–22 bar (261–319 psi) |
Compatibility
This 4657.024.048 complete unit is engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 190, WG 191, and WG 192 models commonly found in 20–30 ton wheel loaders and articulated trucks. While primarily designed for the WG 190 platform, the assembly shares mounting patterns with the WG 180 and WG 200 series, though internal gear ratios differ. Always verify the HOUSING REAR PART alignment and bell housing bolt pattern before installation to ensure proper fitment with your specific vehicle model.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101033 | TRANSMISSION HOUSING | Main structural casing that encloses gear sets and supports bearings |
| 4657201027 | HOUS.FRONT SECT | Front section housing the input shaft and torque converter interface |
| 4657201012 | HOUSING REAR PART | Rear casing that supports output shaft and parking brake assembly |
| 0631306792 | CYLINDRICAL PIN | Precision dowel pin for aligning housing halves during assembly |
| 0636100801 | CAP SCREW | M12 bolt securing the housing front section to the main casing |
| 4656301148 | FIXING PLATE | Locking plate that prevents cap screw loosening under vibration |
| 4657301032 | SCREEN SHEET | Fine mesh filter for the main hydraulic suction line |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for the charge pump inlet |
| 0636100803 | CAP SCREW | M10 bolt used for securing the rear housing cover plate |
| 4681301040 | OIL FEED.HOUSG. | Cast oil distribution manifold directing fluid to clutch packs |
Frequently Asked Questions
Q: Is the ZF 4657.024.048 a direct bolt-in replacement for a WG 190 transmission?
A: Yes, this complete unit is a factory-assembled replacement for the WG 190 series. It includes all internal components and requires only the transfer of external sensors and the bell housing from your original unit.
Q: Can I install this assembly without removing the torque converter?
A: No, the torque converter must be separated from the engine flywheel before installation. The 4657.024.048 unit includes the converter housing, but the converter itself is a separate serviceable component.
Q: What is the typical service life of this complete transmission assembly?
A: Under normal operating conditions with proper fluid maintenance, the assembly can last 8,000–12,000 hours. Harsh environments with heavy shock loading may reduce this interval to 5,000 hours.
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Phone: +86 158 2286 3467 |
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