Overview
This complete ZF 4657.024.119 4 WG 190 Powershift Transmission Assembly is a fully assembled unit designed for heavy-duty off-highway machinery. As the core of the WG 190 series, this assembly integrates the main gear set, clutch packs, and hydraulic control system into a single, ready-to-install package. The SKU 4657.024.119 serves as a direct replacement for worn or failed transmissions in loaders, graders, and industrial vehicles. It sits between the engine bellhousing and the final drive, managing torque distribution across four forward and reverse speeds. For a full rebuild, ensure the TRANSMISSION HOUSING is inspected for cracks, as it provides the structural foundation for this assembly.
Symptoms of Failure
When the ZF 4657.024.119 assembly begins to fail, operators typically notice three distinct issues. First, delayed engagement or gear slipping occurs when internal clutch packs lose hydraulic pressure, causing hesitation during directional shifts. Second, external oil leaks around the housing seams appear, often traced to a compromised HOUS.FRONT SECT gasket surface. Third, abnormal whining or grinding noises from the transmission indicate worn bearings or planetary gear damage. Fourth, erratic shifting or loss of power under load suggests internal seal failure, allowing oil to bypass the torque converter. These symptoms often prompt a full unit replacement rather than partial repairs.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.024.119 |
| Assembly Type | Complete Powershift Unit |
| Weight (estimated) | 185 kg (408 lbs) |
| Dimensions (L x W x H) | 620 x 480 x 420 mm |
| Housing Material | Cast Iron / Aluminum Alloy |
| OEM Reference | ZF WG 190 Series |
| Bolt Torque Spec | Refer to CAP SCREW (0636100801) guidelines |
| Internal Screen | SCREEN SHEET (4657301032) included |
Compatibility
This complete unit is engineered for the ZF WG 190 series, but it also fits select WG 180 and WG 200 models with minor modifications. Specifically, the 4657.024.119 is compatible with WG 190-1, WG 190-2, and WG 190-3 variants used in Volvo L120, Caterpillar 950, and similar loaders. The rear housing interface requires the HOUSING REAR PART (4657201103) for proper alignment. For older WG 180 units, verify the HOUSING REAR PART (4472239184) matches your bellhousing pattern. Always cross-reference your machine’s serial number before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101059 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201132 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201103 | HOUSING REAR PART | Rear housing for output flange |
| 4472239184 | HOUSING REAR PART | Alternate rear housing for WG 180 |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | M10 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Retainer plate for clutch pack |
| 4657301032 | SCREEN SHEET | Oil filter screen (primary) |
| 4657301033 | SCREEN SHEET | Oil filter screen (secondary) |
| 0636100803 | CAP SCREW | M12 bolt for rear housing |
Frequently Asked Questions
Q: Can the 4657.024.119 be rebuilt instead of replaced?
A: Yes, but only if the housing is undamaged. Inspect the TRANSMISSION HOUSING for cracks first. Rebuild kits are available, but a complete unit swap is often more cost-effective for severe internal damage.
Q: What oil type does this assembly require?
A: ZF recommends TE-ML 03 or 05 spec oil (SAE 10W-30 or 15W-40). Always replace the SCREEN SHEET (4657301032) during oil changes to prevent debris circulation.
Q: Does this unit include the torque converter?
A: No, the 4657.024.119 is the transmission assembly only. The torque converter is sold separately. Verify your existing converter matches the input spline pattern.
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Phone: +86 158 2286 3467 |
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