Overview
The ZF 4657.024.160 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway machinery. This assembly integrates the main gear cluster, clutch packs, and hydraulic control components into a single, ready-to-install package. As a core element of the WG 190 series, it manages torque distribution across four forward and reverse speeds. The SKU 4657.024.160 is the direct replacement for worn or failed assemblies in articulated dump trucks, wheel loaders, and graders. This unit interfaces directly with the TRANSMISSION HOUSING to form the structural backbone of the drivetrain.
Symptoms of Failure
- Delayed or harsh engagement: When the 4657.024.160 assembly wears, you may experience a noticeable lag between shifting and actual gear engagement, often accompanied by a jarring clunk.
- Internal oil leaks and pressure loss: Worn seals within the assembly cause transmission fluid to bypass internal circuits, leading to low line pressure and visible drips from the bell housing area.
- Gear slipping under load: A failing unit will allow the transmission to momentarily lose power delivery when climbing grades or pushing heavy loads, a classic sign of worn clutch discs or piston seals.
- Unusual whining or grinding noises: Metallic sounds from the transmission center section indicate bearing or gear tooth damage within the 4657.024.160 assembly.
Technical Specifications
| Specification | Value |
|---|---|
| Part Number | 4657.024.160 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-Grade Cast Iron |
| OEM Reference | ZF 4 WG 190 Series |
| Torque Capacity (max) | 1,200 Nm (885 lb-ft) |
| Number of Speeds | 4 Forward / 4 Reverse |
| Compatible Fastener | CAP SCREW (0636100801) |
| Alignment Component | CYLINDRICAL PIN (0631306816) |
Compatibility
This complete unit is engineered for the ZF WG 190 series powershift transmissions. It is a direct fit for the WG 190, WG 191, and WG 192 models commonly found in construction equipment. While primarily designed for the 190 series, the 4657.024.160 assembly may also be retrofitted into select WG 180 and WG 200 applications with verification of bell housing and output flange dimensions. The assembly mounts securely between the HOUS.FRONT SECT and the HOUSING REAR PART. For extended configurations, the HOUSING REAR SECTION provides additional support for PTO adapters.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201168 | HOUSING REAR PART | Rear housing for output bearing support |
| 4657298101 | HOUSING REAR SECTION | Extended rear housing for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0636100801 | CAP SCREW | M12 fastener for housing joints |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump |
| 0636100803 | CAP SCREW | M10 fastener for valve body attachment |
Frequently Asked Questions
Q: Is the 4657.024.160 a direct bolt-in replacement for the original ZF 4 WG 190?
A: Yes, this complete assembly is manufactured to OEM specifications and includes all internal components. It bolts directly into the existing housing without modification.
Q: What other parts should I inspect when replacing this assembly?
A: Always check the condition of the HOUS.FRONT SECT and HOUSING REAR PART for cracks or wear. Replace the SCREEN SHEET (4657301032) and SCREEN SHEET (4657301033) to prevent debris contamination.
Q: Does this unit include the torque converter?
A: No, the 4657.024.160 is the powershift assembly only. The torque converter is a separate component and must be ordered independently.
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Phone: +86 158 2286 3467 |
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