Overview
The ZF 4657.024.602 4 WG 190 Powershift Transmission Assembly is a complete, factory-engineered unit designed for heavy-duty off-highway applications. This assembly serves as the core power transfer module within the WG 190 series, integrating the main gear train, clutch packs, and hydraulic control system into a single, ready-to-install package. The SKU 4657.024.602 is a direct OEM replacement, ensuring seamless integration with existing driveline configurations. It sits between the torque converter and the output driveline, managing gear ratio changes under full load without power interruption. For a full installation, this unit is typically paired with the 4657130126: ENGINE CONNECTION and the 4657330098: CONVERTER BELL to complete the engine-to-transmission interface.
Symptoms of Failure
When the ZF 4657.024.602 assembly begins to degrade, operators will notice distinct operational issues. Delayed or harsh engagement between forward and reverse gears is a primary indicator, often caused by worn clutch discs or degraded seals within the unit. Another common symptom is erratic shifting under load, where the transmission hunts for gears or slips during acceleration, pointing to hydraulic pressure loss. External oil leaks from the main housing gasket or output seal are also frequent, leading to low fluid levels and eventual overheating. Finally, unusual whining or grinding noises from the gear train, particularly in lower ranges, signal bearing fatigue or gear tooth damage that requires immediate attention.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4657.024.602 |
| Series | WG 190 (4 WG 190) |
| Type | Powershift Transmission Assembly (Complete Unit) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length (approx.) | 620 mm |
| Overall Width (approx.) | 480 mm |
| Overall Height (approx.) | 510 mm |
| Housing Material | High-Grade Cast Iron |
| Input Spline Count | 14-tooth, 2-inch pitch |
| Fluid Capacity | 12.5 liters (ATF Dexron III) |
Compatibility
This complete unit is engineered specifically for the ZF WG 190 series, but its core architecture shares components with adjacent model families. It is directly compatible with WG 180 and WG 200 series transmissions when used with the correct adapter kit. The assembly also fits select WG 160 variants that utilize the same bell housing pattern. For proper sealing and mounting, always install a new 0636100713: HEXAGON SCREW set and the 4657330099: COVER to protect the clutch access port during service.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657130126 | ENGINE CONNECTION | Couples transmission to engine flywheel housing |
| 4657330098 | CONVERTER BELL | Houses torque converter assembly |
| 0636100713 | HEXAGON SCREW | Secures bell housing to transmission case |
| 4657330099 | COVER | Protects clutch access port from debris |
| 0636100801 | CAP SCREW | Fastens valve body and filter housing |
| 0637006281 | HEXAGON NUT | Locks mounting studs on output flange |
| 4657330004 | DIAPHRAGM | Regulates hydraulic pressure in clutch circuits |
| 4657330053 | INPUT SHAFT | Transfers torque from converter to gear train |
| 0636102411 | HEXAGON SCREW | Mounts control valve assembly |
| 0666690022 | JOINTING COMPOUND | Seals mating surfaces to prevent oil leaks |
Frequently Asked Questions
Q: Can the 4657.024.602 be rebuilt, or must it be replaced as a complete unit?
A: While internal components like clutch packs and seals are serviceable, the complete assembly is recommended for maximum reliability. Rebuilding requires specialized tooling and access to OEM shims, which are included only in the complete unit.
Q: What is the typical lifespan of this transmission assembly in a wheel loader?
A: Under normal operating conditions with proper maintenance (fluid changes every 1,000 hours), the 4 WG 190 assembly typically lasts 8,000 to 12,000 hours before requiring major overhaul.
Q: Does this unit include the torque converter?
A: No. The 4657.024.602 is the transmission assembly only. The torque converter is a separate component, and you will need the 4657330098: CONVERTER BELL to mount it correctly.
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