Overview
This complete ZF 4657.024.120 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway machinery. As a core component of the WG 190 series, this assembly manages torque distribution across four forward and reverse speeds, enabling smooth clutch modulation under load. The SKU 4657.024.120 serves as a direct replacement for worn or failed transmissions in wheel loaders, graders, and industrial tractors. It integrates with the 4657101051 TRANSMISSION HOUSING to form the main structural shell, while the 4657201151 HOUS.FRONT SECT and 4657201103 HOUSING REAR PART enclose the planetary gear sets and clutch packs.
Symptoms of Failure
- Delayed or harsh shifting under load: Worn clutch discs or degraded seals inside the 4 WG 190 cause hesitation when engaging gears, particularly during directional changes.
- Hydraulic oil leaks at housing seams: Cracks or gasket failure in the main casing lead to visible fluid loss around the bell housing or rear cover, often accompanied by low pressure warnings.
- Gear slipping during high-torque operations: Internal wear on the planetary carrier or sun gear allows the transmission to momentarily lose drive power when climbing grades or pushing heavy loads.
- Unusual whining or grinding noises: Bearing fatigue or debris contamination in the oil circuit produces metallic sounds that intensify with engine RPM.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight (dry) | 185 kg (408 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | Cast Iron (GGG-40) |
| OEM Reference | ZF 4657.024.120 |
| Max Input Torque | 1,200 Nm |
| Oil Capacity | 14.5 L |
Compatibility
This complete unit is engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with models including the WG 180, WG 190, and WG 200 series used in construction and agricultural equipment. The assembly also fits select variants of the WG 160 series when paired with the correct 4472239184 HOUSING REAR PART. Always verify the original equipment manufacturer (OEM) part number against your machine’s serial plate before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101051 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201151 | HOUS.FRONT SECT | Front section enclosing clutch packs |
| 4657201103 | HOUSING REAR PART | Rear cover for planetary assembly |
| 4472239184 | HOUSING REAR PART | Alternate rear housing variant |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing mating |
| 0636100801 | CAP SCREW | Fastener for housing sections |
| 4656301148 | FIXING PLATE | Secures oil filter assembly |
| 4657301032 | SCREEN SHEET | Fine mesh oil strainer |
| 4657301033 | SCREEN SHEET | Coarse mesh oil strainer |
| 0636100803 | CAP SCREW | High-torque fastener for bell housing |
Frequently Asked Questions
Q: Can this 4 WG 190 assembly be rebuilt, or must it be replaced as a complete unit?
A: While internal components like clutch discs and seals are serviceable, the 4657.024.120 is typically replaced as a complete assembly due to the precision alignment required for the planetary gear sets. Rebuilding is only recommended if you have access to OEM tooling and a certified ZF service center.
Q: What is the expected service life of this transmission before overhaul?
A: Under normal operating conditions with proper oil changes every 1,000 hours, the WG 190 series typically lasts 8,000 to 12,000 hours. Heavy loading or contaminated fluid can reduce this interval significantly.
Q: Does this unit include the torque converter?
A: No, the 4657.024.120 is the powershift transmission assembly only. The torque converter is a separate component and must be ordered independently based on your engine flywheel housing pattern.
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Phone: +86 158 2286 3467 |
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