Overview
This ZF 4657.054.139 4 WG 210 Powershift Transmission Assembly is a complete, ready-to-install unit engineered for heavy-duty off-highway machinery. As the core power transfer module in the WG 210 series, this assembly integrates the main gear set, clutch packs, and hydraulic control system into a single robust package. The SKU 4657.054.139 is the direct replacement for original equipment transmissions in articulated dump trucks, wheel loaders, and graders. When paired with a new TRANSMISSION HOUSING, this unit ensures precise gear engagement under extreme torque loads.
Symptoms of Failure
- Delayed or harsh shifting: Worn internal clutches cause hesitation between forward and reverse gears, often accompanied by a loud bang during engagement.
- Torque converter overheating: A failing assembly leads to excessive slippage, raising transmission fluid temperatures above 120°C (248°F) during normal operation.
- Intermittent power loss under load: The unit may suddenly lose drive on inclines or when carrying rated payloads, indicating worn planetary gears or damaged seals.
- External fluid seepage at housing joints: Cracks in the HOUS.FRONT SECT or HOUSING REAR PART allow ATF to leak onto the bell housing, creating visible drips after shutdown.
Technical Specifications
| Parameter | Value |
|---|---|
| OEM Part Number | 4657.054.139 |
| Assembly Type | 4-speed Powershift (WG 210) |
| Dry Weight (approx.) | 285 kg (628 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-strength cast iron (GGG-40) |
| Max Input Torque | 2,100 Nm |
| Fluid Capacity | 22 liters (ZF TE-ML 03/05) |
| Related Fastener | CAP SCREW (M12 x 1.5) |
| Related Fastener | CAP SCREW (M16 x 2.0) |
| Alignment Component | CYLINDRICAL PIN |
| Mounting Plate | FIXING PLATE |
| Filter Screen (Fine) | SCREEN SHEET (0.25 mm mesh) |
| Filter Screen (Coarse) | SCREEN SHEET (0.50 mm mesh) |
Compatibility
This complete assembly is designed for the ZF WG 210 series, but it also fits select WG 180 and WG 200 applications with minor adapter modifications. Specifically, it is a direct drop-in replacement for models: WG 180 (1998-2005), WG 200 (2001-2010), and all WG 210 variants (2005-present). The unit requires a matching HOUSING REAR SECTION for proper output flange alignment. Always verify your transmission serial number against the ZF parts catalog before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing torque converter |
| 4657201168 | HOUSING REAR PART | Rear casing for output shaft support |
| 4657298101 | HOUSING REAR SECTION | Extended rear section for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating |
| 0636100801 | CAP SCREW | M12 bolt for front housing fastening |
| 4656301148 | FIXING PLATE | Locks clutch pack retaining ring |
| 4657301032 | SCREEN SHEET | Fine mesh filter for valve body |
| 4657301033 | SCREEN SHEET | Coarse mesh filter for sump pickup |
| 0636100803 | CAP SCREW | M16 bolt for rear housing attachment |
Frequently Asked Questions
Q: Can this assembly be installed without removing the torque converter?
A: No. The ZF 4657.054.139 is a complete unit that includes the torque converter. You must separate the engine from the transmission to install this assembly. Always replace the CYLINDRICAL PIN during reinstallation to ensure perfect alignment.
Q: What is the typical service life of this powershift assembly?
A: Under normal operating conditions (non-abrasive environments, proper fluid changes every 1,000 hours), this unit lasts 8,000-12,000 hours. Early failure is often caused by debris bypassing the SCREEN SHEET filters.
Q: Does this part include the fixing plate and cap screws?
A: This assembly ships as a bare unit. You must order the FIXING PLATE and CAP SCREW sets separately for installation.
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Phone: +86 158 2286 3467 |
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