Overview
The ZF 4657.055.104 5 WG 210 Powershift Transmission Assembly is a complete, factory-matched unit designed for heavy-duty off-highway applications. This assembly integrates the full gear train, clutch packs, and hydraulic control system within a single robust housing. As a direct replacement for the WG 210 series, the SKU 4657.055.104 ensures seamless installation and restores original ZF performance. It sits as the core driveline component, transferring engine torque through five forward speeds and one reverse gear. For structural integrity, this assembly mates directly with the TRANSMISSION HOUSING, which provides the main support for all internal components.
Symptoms of Failure
- Delayed or harsh engagement: When the complete unit wears, operators notice a significant lag between shifting and actual gear engagement, often accompanied by a jarring clunk.
- Internal oil leaks and pressure loss: Cracks in the main casing or worn seals cause hydraulic fluid to weep from mating surfaces, leading to low line pressure and erratic shifting.
- Gear slipping under load: Worn clutch packs or damaged planetary gears within the assembly cause the transmission to lose torque during acceleration, especially on inclines.
- Unusual whining or grinding noises: Bearing failure or gear tooth damage produces a high-pitched whine that increases with engine RPM, indicating imminent internal failure.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4657.055.104 |
| Assembly Type | Complete Powershift Unit (5 WG 210) |
| Overall Length | ~680 mm (estimated) |
| Dry Weight | ~195 kg (estimated) |
| Housing Material | High-strength cast iron |
| OEM Reference | ZF 5 WG 210 |
| Torque Capacity | Up to 2100 Nm (estimated) |
| Bolt Torque Spec | Refer to ZF service manual |
Compatibility
This complete unit is engineered for the ZF WG 210 series, but its core architecture shares mounting patterns with the WG 180 and WG 200 families. It is a direct fit for all 5 WG 210 variants used in wheel loaders, forklifts, and telescopic handlers. The assembly requires precise alignment with the HOUS.FRONT SECT and the HOUSING REAR PART to maintain correct gear mesh. For extended rebuilds, the HOUSING REAR SECTION is also compatible when replacing the rear casing separately.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural casing for the gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft support |
| 4657201170 | HOUSING REAR PART | Rear casing section for output bearing retention |
| 4657298102 | HOUSING REAR SECTION | Alternate rear housing for specific WG210 variants |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | M12 fastener for housing-to-bell housing joint |
| 4656301148 | FIXING PLATE | Locks clutch piston housing in position |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic return line |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for suction line |
| 0636100803 | CAP SCREW | M10 bolt for securing the rear cover plate |
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