Overview
This complete ZF 4657.024.309 4 WG 190 Powershift Transmission Assembly is a fully integrated unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 190 series, this assembly manages torque distribution across four forward and reverse speeds. The SKU 4657.024.309 represents a factory-matched assembly that includes the main gear cluster, clutch packs, and hydraulic control system. It sits directly between the engine flywheel and the final drive, converting rotational energy into controlled tractive effort. For structural integrity, this unit integrates with the 4657101085: TRANSMISSION HOUSING which provides the rigid backbone for all internal components.
Symptoms of Failure
- Delayed engagement or gear slipping under load: When the internal clutch packs or hydraulic seals degrade, operators notice hesitation when shifting from neutral to drive, or the transmission slips out of gear during heavy pulling.
- External oil leaks at housing seams: Worn gaskets or cracks in the 4657201161: HOUS.FRONT SECT or the 4657201162: HOUSING REAR PART cause fluid to weep onto the bell housing, leading to low oil levels and overheating.
- Abnormal whining or grinding noises: Bearing wear or gear tooth damage within the assembly produces a high-pitched whine during acceleration or a grinding sound when decelerating.
- Erratic shifting or harsh engagement: Faulty valve body operation or contaminated hydraulic fluid causes sudden, jarring shifts that can damage driveline components.
Technical Specifications
| Specification | Value |
|---|---|
| Assembly Weight (dry) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 410 mm |
| Overall Height | 480 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| Max Input Torque | 1,900 Nm |
| OEM Reference | ZF 4657.024.309 |
| Fluid Capacity | 14.5 liters (ZF EcoFluid M-1) |
| Bolt Torque (housing) | 120 Nm (M12 cap screws) |
Compatibility
This complete unit is specifically engineered for the ZF WG 190 series powershift transmissions. It is directly compatible with WG 180, WG 190, and WG 200 models used in wheel loaders, telehandlers, and industrial tractors. The assembly also fits select variants of the WG 170 series with minor adapter modifications. For proper sealing, the 4657298107: HOUSING REAR SECTION must be correctly aligned to prevent oil migration between chambers.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101085 | TRANSMISSION HOUSING | Main structural casing for gear and clutch assembly |
| 4657201161 | HOUS.FRONT SECT | Front section housing input shaft and pump drive |
| 4657201162 | HOUSING REAR PART | Rear section supporting output shaft and PTO |
| 4657298107 | HOUSING REAR SECTION | End cap with bearing support for final drive |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | M12 x 1.75 bolt for housing flange fastening |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic return line |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for suction line |
| 0636100803 | CAP SCREW | M10 x 1.5 bolt for valve body mounting |
Frequently Asked Questions
Q: Can this assembly be rebuilt, or must it be replaced as a complete unit?
A: While individual clutch packs and seals can be serviced, the ZF 4657.024.309 is typically replaced as a complete unit due to the precision alignment of the planetary gears and hydraulic circuits. Rebuilding requires specialized tooling and is only recommended for shops with ZF certification.
Q: What is the typical service life of this powershift transmission assembly?
A: Under normal operating conditions with proper fluid maintenance (ZF EcoFluid M-1 changed every 1,000 hours), the assembly can last 8,000 to 12,000 hours. Harsh applications like quarry loading or snow removal may reduce this to 5,000-7,000 hours.
Q: Does this unit include the torque converter?
A: No. The 4657.024.309 is the transmission assembly only. The torque converter is a separate component (ZF part number 4657.025.001) that must be ordered independently if needed.
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Phone: +86 158 2286 3467 |
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