Overview
The ZF 4657.024.108 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the main gear cluster, clutch packs, and hydraulic control components into a single, ready-to-install package. As the core power transfer module in the WG 190 Series, it manages torque distribution across four forward and reverse speeds. The SKU 4657.024.108 is a direct OEM replacement, ensuring seamless fitment without modification. This assembly sits between the torque converter and the output driveline, converting hydraulic pressure into mechanical force for precise vehicle control.
Symptoms of Failure
When the ZF 4657.024.108 assembly begins to degrade, operators typically notice these specific failure modes:
- Delayed or harsh gear engagement: Worn clutch discs or piston seals inside the assembly cause hesitation when shifting from neutral to drive or reverse, often accompanied by a jarring clunk.
- Internal oil leaks and pressure loss: Cracks in the TRANSMISSION HOUSING or degraded O-rings within the assembly lead to visible fluid seepage and a drop in line pressure, triggering warning codes.
- Gear slipping under load: As the assembly’s friction material wears, the transmission fails to hold torque during uphill climbs or heavy hauling, causing the engine to rev without proportional vehicle movement.
- Unusual whining or grinding noises: Bearing fatigue or gear tooth damage inside the 4657.024.108 produces a metallic sound that intensifies with speed, indicating imminent internal failure.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.024.108 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Dry Weight | Approx. 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| OEM Reference | ZF 4 WG 190 Series |
| Torque Capacity | Up to 1,900 Nm |
| Fluid Capacity | 12.5 liters (ZF TE-ML 03 spec) |
Compatibility
This complete unit is engineered for the ZF WG 190 Series, but it also fits select models in the WG 180 and WG 200 families due to shared mounting patterns. It is a direct replacement for transmissions used in Schaeff Terex, Liebherr, and Volvo CE wheel loaders and graders. The assembly requires the HOUS.FRONT SECT and HOUSING REAR PART to complete the structural enclosure. For extended rebuilds, the HOUSING REAR SECTION is also interchangeable. Always verify your transmission serial number against ZF’s application guide before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201168 | HOUSING REAR PART | Rear section covering output bearings |
| 4657298101 | HOUSING REAR SECTION | Alternate rear housing variant |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0636100801 | CAP SCREW | M10 fastener for housing bolts |
| 4656301148 | FIXING PLATE | Retainer for clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | M12 fastener for rear housing |
Frequently Asked Questions
Q: Can the 4657.024.108 be installed without removing the entire transmission from the vehicle?
A: No. This is a complete assembly that requires removal of the transmission from the chassis. It is recommended to replace the TRANSMISSION HOUSING and all seals during installation to prevent future leaks.
Q: What is the typical service life of this powershift assembly?
A: Under normal operating conditions with proper fluid maintenance, the ZF 4657.024.108 lasts between 8,000 and 12,000 hours. Harsh environments or frequent heavy loading can reduce this interval.
Q: Does this unit include the torque converter?
A: No. The 4657.024.108 is the transmission assembly only. The torque converter must be ordered separately. Ensure the HOUS.FRONT SECT is compatible with your existing converter model.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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