Overview
This ZF 4657.024.156 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 190 series, this assembly integrates the main gear cluster, clutch packs, and hydraulic control circuits into a single ready-to-install package. The SKU 4657.024.156 serves as the direct replacement for worn or failed transmissions in articulated dump trucks, wheel loaders, and graders. It mates directly with the TRANSMISSION HOUSING to form the structural backbone of the driveline, while the HOUS.FRONT SECT and HOUSING REAR PART enclose the rotating components. This complete unit eliminates the need for piecemeal rebuilding, reducing downtime in critical fleet operations.
Symptoms of Failure
- Delayed or harsh engagement: When the internal clutch packs wear, operators experience a noticeable lag between shifting and power delivery, often accompanied by a jarring thud. This is a primary indicator that the complete assembly requires replacement.
- Torque converter shudder under load: A vibration or shudder during low-speed maneuvering or uphill hauling signals internal wear within the stator or turbine assembly of this unit.
- External oil seepage at housing joints: Leaks developing between the main casing and the HOUSING REAR SECTION indicate seal degradation, leading to low fluid levels and eventual gear starvation.
- Erratic shifting or loss of forward gears: A failing transmission assembly will often drop gears or refuse to shift, leaving the vehicle stranded. This is commonly caused by worn valve body components within the 4657.024.156 unit.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4657.024.156 |
| Assembly Type | 4 WG 190 Powershift (Complete Unit) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 490 mm |
| Housing Material | High-Grade Cast Iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| Fluid Capacity | 22 Liters (ZF TE-ML 03 spec) |
| Related Fastener | CAP SCREW (M12 x 1.5) |
| Related Fastener | CAP SCREW (M16 x 2.0) |
Compatibility
This complete assembly is engineered for the ZF WG 190 series, but its core architecture also supports select variants in the WG 180 and WG 200 families when used with the correct adapter housings. It is a direct fit for all 4-speed WG 190 transmissions found in 20-30 ton articulated haulers and 5-7 cubic yard wheel loaders. For proper sealing, always install a new CYLINDRICAL PIN and FIXING PLATE during reassembly. Additionally, the internal oil circuit requires the SCREEN SHEET (primary) and SCREEN SHEET (secondary) to be replaced simultaneously to prevent debris contamination.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201166 | HOUS.FRONT SECT | Front section enclosing torque converter |
| 4657201168 | HOUSING REAR PART | Rear cover for output shaft assembly |
| 4657298101 | HOUSING REAR SECTION | Extended rear housing for PTO mount |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0636100801 | CAP SCREW | M12 fastener for housing bolts |
| 4656301148 | FIXING PLATE | Locks clutch piston in position |
| 4657301032 | SCREEN SHEET | Primary oil filter mesh |
| 4657301033 | SCREEN SHEET | Secondary oil filter mesh |
| 0636100803 | CAP SCREW | M16 fastener for rear housing |
Frequently Asked Questions
Q: Can I install this 4657.024.156 unit without replacing the housing sections?
A: It is strongly recommended to inspect and replace the TRANSMISSION HOUSING and HOUS.FRONT SECT if they show any cracks or wear, as used housings can cause misalignment and premature failure of the new assembly.
Q: What is the typical service life of this complete transmission assembly?
A: Under normal operating conditions with proper fluid maintenance, the ZF 4 WG 190 assembly typically lasts 8,000 to 12,000 hours before requiring overhaul. Harsh environments or heavy shock loads will reduce this interval.
Q: Are the cap screws included with the assembly?
A: No, the assembly ships without fasteners. You must order the CAP SCREW (M12) and CAP SCREW (M16) separately to secure the housing sections.
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Phone: +86 158 2286 3467 |
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