Overview
The ZF 4657.024.109 4 WG 190 Powershift Transmission Assembly is a complete, remanufactured 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 vehicle control under extreme loads. The SKU 4657.024.109 is the direct replacement for original ZF production units, ensuring exact fitment and OEM-spec performance. This assembly sits at the heart of the drivetrain, connecting the engine output to the final drive via 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 within the assembly cause delayed shifts or complete loss of drive, especially when climbing grades.
- External oil leaks near the bell housing or output flange: Cracks in the HOUS.FRONT SECT or gasket failure lead to visible fluid loss, often mistaken for engine oil leaks.
- Unusual whining or grinding noises during operation: Bearing fatigue or gear tooth damage inside the assembly produces metallic sounds that intensify with speed.
- Delayed or harsh reverse engagement: Hydraulic pressure loss in the rear section, often linked to a failing HOUSING REAR PART, results in jarring shifts.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight (dry) | ~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 4657.024.109 |
| Max Input Torque | 1,900 Nm |
| Oil Capacity | 22 liters (SAE 10W-30) |
| Bolt Torque (housing) | 120 Nm (M12 cap screws) |
Compatibility
This complete unit is engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with models WG 180, WG 190, and WG 200, which are commonly found in telescopic handlers, wheel loaders, and rough-terrain forklifts. The assembly also fits select WG 210 variants when paired with the correct HOUSING REAR PART adapter. Always verify the serial number prefix (4 WG 190) against your machine’s transmission tag before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101051 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201151 | HOUS.FRONT SECT | Front section housing input shaft and pump drive |
| 4657201103 | HOUSING REAR PART | Rear section enclosing output shaft and parking brake |
| 4472239184 | HOUSING REAR PART | Alternate rear housing for WG 200/210 variants |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing-to-housing mating |
| 0636100801 | CAP SCREW | M12 x 1.75 bolt for housing flange fastening |
| 4656301148 | FIXING PLATE | Locks bearing preload and prevents axial movement |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit (primary) |
| 4657301033 | SCREEN SHEET | Fine mesh filter for hydraulic circuit (secondary) |
| 0636100803 | CAP SCREW | M10 x 1.5 bolt for cover plate attachment |
Frequently Asked Questions
Q: Can the ZF 4657.024.109 be installed without replacing the housing sections?
A: It is strongly recommended to inspect and replace the TRANSMISSION HOUSING and both front/rear sections if they show cracks or wear, as these directly affect alignment and oil sealing.
Q: What is the typical service life of this complete assembly?
A: Under normal operating conditions with proper oil changes, the 4 WG 190 assembly lasts 8,000–10,000 hours. Failure of the HOUS.FRONT SECT or HOUSING REAR PART often shortens this lifespan due to misalignment.
Q: Does this unit include the screen sheets and fixing plate?
A: No, the assembly is sold as a complete unit but does not include consumable filters or hardware. You must order the SCREEN SHEET (4657301032) and FIXING PLATE separately for a full rebuild.
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Phone: +86 158 2286 3467 |
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