Overview
The ZF 4657.055.001 5 WG 210 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 valve body within a single robust housing. As the central power distribution module, it sits between the engine and the final drive, converting torque into controlled wheel or track motion. The SKU 4657.055.001 denotes a factory-remanufactured or new complete assembly, ensuring direct replacement without the need for sub-component matching. When installing this unit, it is critical to pair it with a properly sealed 4657101033: TRANSMISSION HOUSING to maintain oil integrity and structural alignment.
Symptoms of Failure
- Erratic gear engagement or slipping under load: Worn clutch discs or valve body degradation within the 5 WG 210 cause delayed shifts or complete loss of drive in specific ranges.
- External oil leaks near the bell housing or rear seal: Cracks in the main casing or degraded gaskets allow transmission fluid to escape, often visible as drips after shutdown.
- Unusual whining or grinding noises during operation: Bearing fatigue or gear tooth pitting inside the assembly generates metallic sounds that intensify with speed.
- Overheating and burnt fluid smell: Internal slippage or blocked oil passages cause excessive heat, leading to dark, acrid-smelling transmission oil.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Weight | Approx. 185 kg (408 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | Cast iron (GGG-40) |
| OEM Reference | ZF 4657.055.001 |
| Torque Capacity | 2,100 Nm (max) |
| Number of Speeds | 5 forward / 1 reverse |
| Oil Capacity | 22 liters (SAE 10W-30) |
Compatibility
This complete unit is engineered for the ZF WG 210 series powershift transmissions. It is directly compatible with models including the WG180, WG200, and WG210 variants used in wheel loaders, forklifts, and telehandlers from manufacturers such as Caterpillar, Volvo, and JCB. The assembly also fits select ZF 4WG-210 and 5WG-210 configurations. For proper front-end sealing, always install the 4657201027: HOUS.FRONT SECT and the 4657201012: HOUSING REAR PART to complete the enclosure. Secure the assembly using a 0631306792: CYLINDRICAL PIN for precise dowel alignment during installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101033 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201027 | HOUS.FRONT SECT | Front section housing for input shaft and pump drive |
| 4657201012 | HOUSING REAR PART | Rear section enclosing output shaft and parking brake |
| 0631306792 | CYLINDRICAL PIN | Alignment dowel for precise housing mating |
| 0636100801 | CAP SCREW | M12 fastener for housing bolt connections |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil sump debris |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for hydraulic circuit |
| 0636100803 | CAP SCREW | M10 fastener for valve body mounting |
| 4681301040 | OIL FEED.HOUSG. | Oil distribution manifold for clutch lubrication |
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