ZF 4657.024.052 4 WG 190 Powershift Transmission Assembly | Complete Unit

Overview

This ZF 4657.024.052 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 190 series, this assembly integrates the torque converter, planetary gear sets, and clutch packs into a single, ready-to-install package. The SKU 4657.024.052 replaces worn or failed complete transmissions, restoring full forward and reverse shuttle capability in loaders, dozers, and graders. It sits directly between the engine flywheel housing and the final drive, ensuring seamless power delivery under extreme loads.

Symptoms of Failure

• Delayed or harsh engagement: When the complete unit wears, operators experience a noticeable lag or violent clunk when shifting from forward to reverse, indicating internal clutch pack wear.
• Torque converter shudder under load: A vibration or shudder during acceleration at low speeds suggests stator or turbine damage within the 4657.024.052 assembly.
• External oil leaks near the bell housing: Worn seals and gaskets in the complete unit cause hydraulic fluid to weep from the joint between the TRANSMISSION HOUSING and the engine adapter.
• Loss of directional control: If the machine creeps or fails to hold a gear on an incline, the internal clutches or one-way sprags in the assembly have failed.

Technical Specifications

Compatibility

This complete unit is engineered for the ZF WG 190 series, but it also directly replaces assemblies in the WG 180 and WG 200 series due to shared bolt patterns and clutch diameters. It is commonly found in Volvo L120/L150 loaders, Case 921E wheel loaders, and John Deere 844K graders. The 4657.024.052 mates with the HOUS.FRONT SECT and the HOUSING REAR PART to form the complete structural case. During installation, the CYLINDRICAL PIN must be aligned to ensure proper gear mesh. For machines originally equipped with a WG 180, verify the output flange pattern before ordering.

Related Components

Frequently Asked Questions

Q: Can the 4657.024.052 be rebuilt, or must it be replaced as a complete unit?
A: While individual clutch packs and seals can be serviced, ZF recommends replacing this assembly as a complete unit when internal wear is extensive. The 4 WG 190 case bores and valve body passages are matched at the factory, and reusing a worn housing can lead to premature failure of new components.

Q: What is the typical service life of this complete transmission assembly?
A: Under normal operating conditions with proper oil changes every 1,000 hours, the 4657.024.052 can last 8,000 to 12,000 hours. Harsh applications like rock quarry loading or snow removal may reduce this to 5,000 hours.

Q: Does this unit include the torque converter?
A: Yes, the 4657.024.052 is a full powershift assembly that includes the torque converter, all planetary gears, and the hydraulic valve body. You only need to add the TRANSMISSION HOUSING and external oil cooler lines to complete the installation.