Overview
The ZF 4657.024.104 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the full gear train, clutch packs, and hydraulic control system into a single, ready-to-install package. As a core component of the WG 190 Series, it manages torque distribution across four forward and reverse speeds, enabling precise machine control under extreme loads. The SKU 4657.024.104 replaces worn or failed assemblies, restoring original ZF performance and reliability. This unit sits at the heart of the driveline, connecting directly to the engine and final drive through the TRANSMISSION HOUSING, which provides structural integrity and oil containment.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or degraded seals inside the 4657.024.104 cause delayed or incomplete shifts, especially during uphill travel or heavy digging.
- Hydraulic oil leaks at housing seams: Cracks or gasket failures in the HOUS.FRONT SECT or HOUSING REAR PART allow pressurized oil to escape, leading to low line pressure and eventual transmission overheating.
- Unusual whining or grinding noises from the bell housing: Bearing wear or planetary gear damage within the assembly produces metallic sounds that intensify with engine RPM.
- Loss of reverse or high-range gears: Internal hydraulic circuit blockages or solenoid failures prevent specific clutch packs from engaging, leaving the machine stuck in a single gear range.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4657.024.104 |
| Assembly Type | Complete Powershift Transmission |
| Series | WG 190 |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 410 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| OEM Reference | ZF 4657.024.104 |
| Related Housing Part | 4472239184: HOUSING REAR PART |
| Fastener Spec | 0636100801: CAP SCREW (M12 x 1.75) |
| Alignment Pin | 0631306816: CYLINDRICAL PIN |
| Retention Plate | 4656301148: FIXING PLATE |
| Oil Filter Screens | 4657301032: SCREEN SHEET / 4657301033: SCREEN SHEET |
| Additional Fastener | 0636100803: CAP SCREW (M16 x 2.0) |
Compatibility
This complete assembly is engineered for the ZF WG 190 Series, specifically the 4 WG 190 variant. It is also backward-compatible with earlier WG 180 models after verifying bell housing bolt patterns, and forward-compatible with WG 200 units when used with the appropriate HOUS.FRONT SECT adapter. Common applications include ZF WG 190, WG 180, WG 200, and select WG 170 configurations found in telescopic handlers, wheel loaders, and rough-terrain forklifts. Always cross-reference the original transmission serial number against the 4657.024.104 to confirm spline count and clutch pack stack height.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101051 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201151 | HOUS.FRONT SECT | Front section housing for input shaft and pump drive |
| 4657201103 | HOUSING REAR PART | Rear housing covering output shaft and parking brake |
| 4472239184 | HOUSING REAR PART | Alternate rear housing variant for specific gear ratios |
| 0631306816 | CYLINDRICAL PIN | Precision alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | M12 fastener for securing housing sections |
| 4656301148 | FIXING PLATE | Locking plate to prevent fastener loosening under vibration |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic return line |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for suction line |
| 0636100803 | CAP SCREW | M16 fastener for heavy-duty housing joints |
Frequently Asked Questions
Q: Can the 4657.024.104 be installed without replacing the housing sections?
A: Yes, but only if the existing TRANSMISSION HOUSING and HOUS.FRONT SECT show no cracks or bore wear. ZF recommends replacing all gaskets and seals when swapping the complete assembly.
Q: What is the typical service life of this complete unit?
A: Under normal operating conditions with proper oil maintenance, the 4657.024.104 can last 8,000–12,000 hours. Premature failure often results from contaminated hydraulic fluid or neglected screen cleaning (see SCREEN SHEET parts).
Q: Does this assembly include the rear housing?
A: No. The HOUSING REAR PART (4657201103) or 4472239184 must be ordered separately if your application requires a replacement.
📞 Need this part? Contact our ZF specialists:
Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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