Overview
The ZF 4657.035.006 5 WG 191 Powershift Transmission Assembly | Complete Unit is a fully assembled, drop-in ready gearbox core designed for heavy-duty off-highway machinery. This complete unit integrates the main drive train, clutch packs, and hydraulic control system within a single robust housing. As a key component in the WG 191 Series, it delivers reliable torque multiplication and smooth directional shifts under extreme loads. The SKU 4657.035.006 is the direct OEM reference for this assembly, ensuring precise fitment without modification. The unit sits between the engine flywheel and the final drive, managing power distribution through five forward speeds. For structural integrity, this assembly relies on the 4657101049: TRANSMISSION HOUSING to enclose all rotating elements, while the 4657301130: HOUS.FRONT SECT and 4657301131: HOUSING REAR PART provide critical alignment for the input and output shafts.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or degraded seals inside the assembly cause delayed shifts or loss of torque during operation.
- External oil leaks at housing joints: Cracks or gasket failure in the main casing lead to fluid seepage, often visible around the bell housing or rear cover.
- Unusual grinding or whining noises: Bearing fatigue or gear tooth damage within the complete unit produces metallic sounds that intensify with speed changes.
- Overheating transmission fluid: Internal debris or blocked oil passages restrict cooling, causing the unit to run hot and trigger warning lights.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.035.006 |
| Assembly Type | Complete Powershift Unit |
| Series | WG 191 |
| Overall Length | ~780 mm |
| Dry Weight | ~185 kg |
| Housing Material | High-Grade Cast Iron |
| OEM Reference | ZF 4657.035.006 |
| Input Spline Count | 14-tooth, SAE 3 |
| Max Torque Capacity | 1,200 Nm |
Compatibility
This complete unit is engineered for the ZF WG 191 Series powershift transmissions. Based on its architecture and part numbering, it is also compatible with select models in the WG 180 and WG 200 families, provided the housing interfaces match. It directly replaces units in ZF WG 191 applications used in wheel loaders, telehandlers, and industrial tractors. Always verify the bell housing pattern and output flange configuration before installation. The assembly is secured using a 0631306816: CYLINDRICAL PIN for precise dowel alignment during mounting.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101049 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657301130 | HOUS.FRONT SECT | Front section housing input shaft and bearings |
| 4657301131 | HOUSING REAR PART | Rear section enclosing output shaft and PTO drive |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636102489 | CAP SCREW | Fastener for securing housing flanges |
| 4656301148 | FIXING PLATE | Locking plate for clutch pack retention |
| 0636102463 | CAP SCREW | Bolt for front section attachment |
| 4657201133 | SCREEN SHEET | Filter mesh for hydraulic fluid debris |
| 0636115287 | CAP SCREW | High-tensile bolt for rear cover |
| 4657301065 | PLATE | Spacer plate for valve body mounting |
