Overview
This complete ZF 4657.024.103 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core of the WG 190 series, this assembly manages torque distribution across four forward and reverse speeds, ensuring smooth clutch engagement under load. The SKU 4657.024.103 replaces the entire gear train and hydraulic control system, making it a direct drop-in solution for machines requiring a complete transmission overhaul. It integrates directly with the TRANSMISSION HOUSING to form the main structural backbone, while the HOUS.FRONT SECT and HOUSING REAR PART enclose the planetary gear sets. This assembly is engineered for minimal downtime in construction and mining equipment.
Symptoms of Failure
- Delayed or harsh gear engagement: Worn clutch packs inside the assembly cause hesitation when shifting from neutral to drive, often accompanied by a loud clunk.
- Torque converter shudder under load: A vibrating sensation during acceleration indicates internal seal degradation or bearing wear within the unit.
- External oil seepage at housing joints: Leaks around the mating surfaces of the HOUSING REAR SECTION signal that the main gasket has failed, leading to low fluid levels.
- Intermittent loss of power in higher gears: Slipping in 3rd or 4th gear points to worn piston seals or a damaged valve body within the 4657.024.103 assembly.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.024.103 |
| Assembly Type | 4 WG 190 Powershift Transmission (Complete Unit) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 560 mm |
| Housing Material | High-Grade Cast Iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| Fluid Capacity | 28 Liters (SAE 10W-30) |
| Related Fastener | CAP SCREW (M12 x 1.5) |
| Related Alignment Pin | CYLINDRICAL PIN (8×20 mm) |
| Retention Plate | FIXING PLATE |
| Filter Screen (Fine) | SCREEN SHEET (100 micron) |
| Filter Screen (Coarse) | SCREEN SHEET (200 micron) |
| Secondary Fastener | CAP SCREW (M10 x 1.25) |
Compatibility
This complete unit is specifically designed for the ZF WG 190 series. It is a direct fit for the 4 WG 190 model and is mechanically compatible with the 4 WG 180 and 4 WG 200 variants when used with the appropriate adapter plate. The assembly shares the same bellhousing bolt pattern as the WG 180 series but has a higher torque capacity suited for the WG 200. It is commonly found in ZF ErgoPower and Ecolife off-highway transmissions used in wheel loaders, graders, and dump trucks from manufacturers such as Volvo, Liebherr, and Caterpillar.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing the torque converter and pump drive |
| 4657201168 | HOUSING REAR PART | Rear casing enclosing the output shaft and parking brake |
| 4657298101 | HOUSING REAR SECTION | Extended rear section for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | M12 fastener for main housing bolts |
| 4656301148 | FIXING PLATE | Retention plate for clutch piston assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump pickup |
| 0636100803 | CAP SCREW | M10 fastener for valve body mounting |
Frequently Asked Questions
Q: Can the 4657.024.103 assembly be rebuilt, or is it only sold as a complete unit?
A: This SKU is sold as a complete, pre-assembled unit. While individual internal components like clutch discs and seals are available separately, the 4657.024.103 is factory-tested and balanced for immediate installation, reducing rebuild labor costs.
Q: What is the difference between this 4 WG 190 unit and the 4 WG 180 version?
A: The 4 WG 190 has a higher torque capacity (1,900 Nm vs. 1,600 Nm) and uses a larger diameter clutch pack. The housing bolt pattern is identical, but the 190 series requires the HOUS.FRONT SECT from the 190 line to accommodate the larger torque converter.
Q: Does this assembly include the necessary cap screws and alignment pins?
A: No, the 4657.024.103 ships as a bare assembly. You will need to order the CAP SCREW (0636100801) and CYLINDRICAL PIN (0631306816) separately for installation.
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