Overview
The ZF 4657.024.308 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 the core rotating assembly within the WG 190 series, it transfers engine torque through four forward speeds and one reverse range, enabling precise power modulation under load. The SKU 4657.024.308 replaces worn or failed internal assemblies, restoring full shift quality and driveline efficiency. This complete unit eliminates the need for piecemeal rebuilding, reducing downtime for construction, mining, and agricultural equipment.
Symptoms of Failure
When the ZF 4657.024.308 assembly begins to fail, operators typically notice three to four distinct performance issues. Delayed or harsh engagement between forward and reverse gears is a common early sign, often accompanied by a noticeable “clunk” during direction changes. Intermittent gear slipping under load occurs as clutch pack friction material degrades, causing the transmission to lose torque on inclines or during heavy pulling. Contaminated transmission fluid with metallic debris indicates internal bearing or gear wear, which can be confirmed by inspecting the magnetic drain plug. Finally, erratic shift patterns or failure to hold a selected gear point to hydraulic pressure loss within the assembly, requiring immediate replacement of the complete unit to prevent secondary damage to the TRANSMISSION HOUSING.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4657.024.308 |
| Assembly Type | Complete Powershift Unit (4 WG 190) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Primary Material | Heat-treated alloy steel / Cast iron |
| Number of Speeds | 4 Forward / 1 Reverse |
| Max Input Torque (est.) | 1,900 Nm |
| Hydraulic Pressure Range | 18–22 bar |
Compatibility
This complete assembly is engineered specifically for the ZF WG 190 series powershift transmissions. It is directly compatible with the WG 190 model and shares mounting interfaces with the WG 180 and WG 200 variants when used with the appropriate adapter components. The 4657.024.308 unit is commonly specified for ZF 4 WG 190 installations in telehandlers, wheel loaders, and dump trucks from manufacturers such as Liebherr, JCB, and Volvo CE. For proper installation, ensure the HOUS.FRONT SECT and HOUSING REAR PART are inspected for wear. In some configurations, the HOUSING REAR SECTION must also be replaced simultaneously to maintain correct alignment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101085 | TRANSMISSION HOUSING | Main structural casing that encloses the gear train and supports all internal components. |
| 4657201161 | HOUS.FRONT SECT | Front section of the housing that aligns the input shaft and pump drive. |
| 4657201162 | HOUSING REAR PART | Rear housing segment that contains the output shaft bearing and PTO mount. |
| 4657298107 | HOUSING REAR SECTION | Extended rear cover that seals the final drive and houses the speed sensor. |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for precise positioning of housing sections during assembly. |
| 0636100801 | CAP SCREW | High-tensile fastener used to secure the housing flanges. |
| 4656301148 | FIXING PLATE | Locking plate that prevents cap screw loosening under vibration. |
| 4657301032 | SCREEN SHEET | Fine mesh filter for the main hydraulic suction line. |
| 4657301033 | SCREEN SHEET | Secondary filter screen for the lubrication circuit. |
| 0636100803 | CAP SCREW | M12 x 1.75 bolt for clutch pack retention. |
Frequently Asked Questions
Q: Can the 4657.024.308 assembly be rebuilt, or must it be replaced as a complete unit?
A: While individual clutch packs and seals are serviceable, the 4657.024.308 is designed as a balanced rotating assembly. Replacing it as a complete unit is strongly recommended to avoid mismatched wear patterns that can cause premature failure of the TRANSMISSION HOUSING.
Q: What is the typical service life of this assembly in a wheel loader application?
A: Under normal operating conditions with proper fluid maintenance, the 4 WG 190 assembly typically lasts 8,000 to 12,000 hours. Harsh environments or frequent direction changes can reduce this interval.
Q: Does this part include the valve body or torque converter?
A: No. The 4657.024.308 is the internal rotating assembly only. The valve body, torque converter, and external housings such as the HOUS.FRONT SECT must be ordered separately if needed.
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