Overview
This ZF 4657.024.138 4 WG 190 Powershift Transmission Assembly is a complete, ready-to-install unit designed for heavy-duty industrial applications. As the core of the WG 190 series, this assembly integrates the main gear set, clutch packs, and hydraulic control system into a single, robust package. The SKU 4657.024.138 replaces worn or failed transmissions, restoring full power flow and shift quality in loaders, graders, and material handlers. It sits directly between the engine flywheel housing and the final drive, serving as the primary torque multiplication and speed reduction component.
Symptoms of Failure
- Delayed or harsh engagement: When the assembly wears, operators notice a significant lag when shifting from neutral to forward or reverse, often accompanied by a jarring clunk.
- Intermittent gear slipping under load: A worn unit causes the transmission to lose torque during heavy pushing or climbing, with the engine revving but vehicle speed dropping.
- External oil seepage at housing joints: Fatigue in the main casing leads to fluid leaks around the mating surfaces, particularly near the bell housing and rear cover, leaving puddles under the machine.
- Unusual whining or grinding noises: Internal bearing or gear damage produces a high-pitched whine that intensifies with engine RPM, signaling imminent failure of the rotating assembly.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.024.138 |
| Series | WG 190 (4-speed Powershift) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 580 mm |
| Housing Material | High-strength cast iron |
| Input Spline Count | 14-tooth, 2.5-inch diameter |
| Output Flange Type | SAE C (6-bolt pattern) |
| Fluid Capacity | 22 liters (5.8 gallons) |
| Max Input Torque | 1,900 Nm |
Compatibility
This complete assembly is engineered for the ZF WG 190 series. It is directly compatible with WG 190 models used in Volvo L120, L150, and L180 wheel loaders, as well as certain Case 921E and 1021F machines. While primarily designed for the WG 190, the 4657.024.138 can also be adapted to WG 180 and WG 200 series transmissions with minor modifications to the bell housing and output yoke. Always verify the original equipment manufacturer (OEM) tag on your existing unit before ordering.
When installing this assembly, it is critical to inspect the supporting structural components. The TRANSMISSION HOUSING (4657101065) must be free of cracks, while the HOUS.FRONT SECT (4657201132) and HOUSING REAR PART (4657201152) should be checked for warpage. Additionally, the HOUSING REAR SECTION (4657298092) often requires replacement if the output bearing bore is worn.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101065 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201132 | HOUS.FRONT SECT | Front section housing the input shaft and pump drive |
| 4657201152 | HOUSING REAR PART | Rear casing enclosing the output shaft and parking brake |
| 4657298092 | HOUSING REAR SECTION | Intermediate rear section for bearing and seal retention |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for precise housing mating |
| 0636100801 | CAP SCREW | Fastener for securing housing sections |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit protection |
| 4657301033 | SCREEN SHEET | Secondary filter screen for oil return line |
| 0636100803 | CAP SCREW | High-tensile bolt for output flange attachment |
Frequently Asked Questions
Q: Can the 4657.024.138 be rebuilt, or is it only sold as a complete unit?
A: This SKU is supplied as a complete, factory-assembled unit. While internal components like clutch discs and seals are available separately, we recommend installing the complete assembly to ensure proper clearances and avoid core handling fees.
Q: What is the typical lead time for this transmission assembly?
A: As a high-demand item, the 4657.024.138 is typically in stock. Standard ground shipping within the continental US takes 3-5 business days. Expedited air freight is available upon request for critical downtime situations.
Q: Does this assembly include the torque converter?
A: No, the torque converter is not included. This unit is the transmission proper. You will need to order the matching ZF torque converter separately, referencing your machine’s engine flywheel housing size.
📞 Need this part? Contact our ZF specialists:
Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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