Overview
This ZF 4657.024.125 4 WG 190 Powershift Transmission Assembly is a complete, factory-engineered unit designed for heavy-duty off-highway applications. As the core power delivery module in the WG 190 series, this assembly integrates the torque converter, planetary gear sets, and clutch packs into a single, ready-to-install package. The SKU 4657.024.125 is a direct replacement for original equipment, ensuring precise fitment and reliable hydraulic pressure control. It sits as the central drivetrain component, transferring engine torque to the output shaft while managing gear ratio changes under load.
Symptoms of Failure
- Delayed or harsh engagement: When the complete unit wears, operators often experience a noticeable lag between shifting and actual gear engagement, or a jarring “clunk” when the clutches lock up.
- Torque converter shudder: A vibration or shudder during acceleration, particularly under heavy load, indicates internal wear within the 4 WG 190 assembly.
- Hydraulic pressure loss and overheating: Worn seals or valve body issues inside the unit cause low line pressure, leading to transmission overheating and erratic shift patterns.
- External oil seepage at housing joints: Leaks often develop where the TRANSMISSION HOUSING meets the HOUS.FRONT SECT, indicating gasket or seal failure within the assembly.
Technical Specifications
| Parameter | Specification |
|---|---|
| Assembly Weight | Approx. 195 kg (430 lbs) |
| Overall Length | 685 mm |
| Overall Width | 420 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| OEM Reference | ZF 4657.024.125 |
| Torque Capacity | Up to 1,900 Nm |
| Fluid Capacity | Approx. 18 liters (with cooler) |
Compatibility
This complete unit is engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 190 models used in wheel loaders, forklifts, and telehandlers. The assembly also fits select WG 180 and WG 200 variants when used with the correct HOUSING REAR PART (4657201103) or the alternative HOUSING REAR PART (4472239184). Always verify your existing housing configuration before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101051 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201151 | HOUS.FRONT SECT | Front section housing the torque converter |
| 4657201103 | HOUSING REAR PART | Rear casing for output shaft and PTO mounting |
| 4472239184 | HOUSING REAR PART | Alternate rear housing for specific gear ratios |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | M12 fastener for housing sections |
| 4656301148 | FIXING PLATE | Retaining plate for clutch piston |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for oil sump |
| 0636100803 | CAP SCREW | M10 fastener for valve body mounting |
Frequently Asked Questions
Q: Is this 4 WG 190 assembly a direct bolt-in replacement for my existing unit?
A: Yes, the 4657.024.125 is a complete drop-in assembly for WG 190 transmissions. Ensure your vehicle uses the correct rear housing variant; you may need the HOUSING REAR PART (4657201103) or 4472239184 for full compatibility.
Q: What maintenance items should I replace when installing this complete unit?
A: We recommend installing new CYLINDRICAL PIN (0631306816) and fresh CAP SCREW (0636100801) fasteners. Also replace both SCREEN SHEET filters (4657301032 and 4657301033) to protect the new assembly from debris.
Q: Can I use this unit in a ZF WG 180 or WG 200 transmission?
A: It is primarily designed for WG 190, but with the correct rear housing adapter, it can fit some WG 180 and WG 200 applications. Verify your transmission serial number and housing part numbers before installation.
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Phone: +86 158 2286 3467 |
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