Overview
This ZF 4657.024.302 4 WG 190 Powershift Transmission Assembly is a complete, factory-engineered unit designed for heavy-duty off-highway applications. As the core of the WG 190 series, this assembly integrates the main gear cluster, clutch packs, and hydraulic control system into a single, ready-to-install package. The SKU 4657.024.302 replaces the need for individual component rebuilding, ensuring precise gear engagement and torque distribution across all four forward speeds. It sits directly between the engine bellhousing and the final drive, managing power flow through the transmission housing and supporting structures.
Symptoms of Failure
When this complete unit begins to fail, operators often notice delayed or harsh gear engagement during directional shifts, a classic sign of worn clutch packs or hydraulic pressure loss. Another common symptom is intermittent slipping under load, particularly when climbing grades or pushing heavy material, which indicates internal seal degradation. You may also observe contaminated transmission fluid with metallic debris, signaling gear tooth wear or bearing failure within the assembly. Finally, external oil leaks at the housing seams often develop as gaskets compress, requiring inspection of the TRANSMISSION HOUSING and adjacent sections.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.024.302 |
| Assembly Type | Complete Powershift Unit |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 410 mm |
| Housing Material | High-Strength Cast Iron |
| Clutch Type | Wet Multi-Plate |
| OEM Reference | ZF 4 WG 190 |
| Related Fastener | CAP SCREW (0636100801) |
| Related Fastener | CAP SCREW (0636100803) |
| Alignment Component | CYLINDRICAL PIN (0631306816) |
| Mounting Plate | FIXING PLATE (4656301148) |
Compatibility
This complete assembly is engineered specifically for the ZF WG 190 series, including the 4 WG 190 variant. It is also compatible with the WG 180 and WG 200 series transmissions when used with the appropriate HOUS.FRONT SECT and HOUSING REAR PART. For applications requiring a different rear mounting configuration, the HOUSING REAR SECTION can be substituted. Common applications include telehandlers, wheel loaders, and industrial tractors from manufacturers like Manitou, JCB, and Caterpillar.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101085 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201161 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201162 | HOUSING REAR PART | Rear section for output bearing support |
| 4657298107 | HOUSING REAR SECTION | Alternate rear housing for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0636100801 | CAP SCREW | M10 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Retainer for clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for oil pump |
| 0636100803 | CAP SCREW | M12 bolt for rear housing mounting |
Frequently Asked Questions
Q: Can this assembly be installed without removing the transmission housing?
A: No. The complete unit requires removal of the TRANSMISSION HOUSING for proper alignment. We recommend replacing the housing gasket and all CAP SCREW fasteners during installation.
Q: What is the typical service life of the 4657.024.302 assembly?
A: With proper maintenance and clean hydraulic fluid, this unit typically lasts 8,000–12,000 operating hours. Regular inspection of the SCREEN SHEET filters is critical to prevent contamination damage.
Q: Does this assembly include the front and rear housing sections?
A: No. The complete unit includes the internal gear train and clutch packs only. You must order the HOUS.FRONT SECT and HOUSING REAR PART separately if needed.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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