Overview
This ZF 4657.024.161 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit engineered for heavy-duty off-highway machinery. As the core power delivery module in the WG 190 series, this assembly integrates the torque converter, planetary gear sets, and hydraulic control system into a single, ready-to-install package. The SKU 4657.024.161 replaces worn or failed original transmissions, restoring full forward/reverse shuttle capability and precise speed control in loaders, dozers, and material handlers. It sits directly between the engine flywheel housing and the final drive, transmitting torque through four forward and four reverse speeds. For a full rebuild, pair this unit with a new TRANSMISSION HOUSING (4657101078) to ensure proper alignment of all internal components.
Symptoms of Failure
When this ZF 4 WG 190 assembly begins to fail, operators typically notice these specific issues:
- Delayed or harsh engagement – A noticeable lag when shifting from neutral to forward or reverse, often accompanied by a jarring clunk. This indicates worn clutch packs or degraded seals inside the 4657.024.161 unit.
- Oil leaks at the bell housing – Fluid weeping from the seam between the transmission and engine, often caused by a cracked HOUS.FRONT SECT (4657201166) or a failed input shaft seal.
- Gear slipping under load – The transmission momentarily loses drive power when climbing grades or pushing heavy loads, a classic sign of worn clutches or a failing torque converter stator.
- Overheating transmission fluid – Consistently high oil temperatures (above 120°C) even with proper cooler flow, often traced to internal leakage past the HOUSING REAR PART (4657201168) seals.
Technical Specifications
| Specification | Value |
|---|---|
| OEM Part Number | 4657.024.161 |
| Series | WG 190 (4 WG 190) |
| Type | Powershift Transmission Assembly (Complete Unit) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 580 mm |
| Housing Material | High-grade cast iron (GGG-40) |
| Input Spline | SAE 14″ (14T, 12/24 pitch) |
| Fluid Capacity | 22 liters (ZF EcoFluid M-1) |
| OEM Reference | ZF 4657.024.161 |
Compatibility
This complete unit is specifically designed for the ZF WG 190 series powershift transmissions. It is a direct fit for the following models and their sub-variants:
- ZF 4 WG 190 – 4-speed forward / 4-speed reverse (primary application)
- ZF 4 WG 180 – Earlier generation (mechanical shift adaptation requires housing swap)
- ZF 4 WG 200 – Higher torque variant (same bell housing pattern, different clutch packs)
- ZF 4 WG 210 – Heavy-duty mining version (identical mounting points)
When installing this 4657.024.161 assembly, always inspect the HOUSING REAR SECTION (4657298101) for cracks, as this component bears the load of the output shaft.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural case for gear train |
| 4657201166 | HOUS.FRONT SECT | Front bell housing section |
| 4657201168 | HOUSING REAR PART | Rear housing for output shaft |
| 4657298101 | HOUSING REAR SECTION | Extended rear housing section |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing mating |
| 0636100801 | CAP SCREW | M12 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Locks clutch pack retaining nuts |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | M10 bolt for cover plates |
Frequently Asked Questions
Q: Can I install this 4657.024.161 assembly without replacing the torque converter?
A: It is strongly recommended to replace the torque converter simultaneously. The complete unit includes the converter, but if you are reusing an old one, inspect the stator splines and pump drive hub for wear.
Q: What is the expected service life of this ZF 4 WG 190 transmission?
A: With proper maintenance (oil changes every 500 hours and filter replacement), this assembly typically lasts 8,000 to 12,000 operating hours in moderate applications like wheel loaders. Heavy rock-handling duty may reduce this to 5,000 hours.
Q: Does this part include the electronic shift controller?
A: No. The 4657.024.161 is a mechanical-hydraulic assembly. It requires an external ZF TCU (transmission control unit) for electronic shift control, sold separately.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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