Overview
The ZF 4657.055.112 5 WG 210 Powershift Transmission Assembly | Complete Unit is a fully integrated, factory-matched gearbox core designed for heavy-duty off-highway machinery. This complete assembly serves as the central power distribution hub, converting engine torque into precise, multi-speed forward and reverse motion. The SKU 4657.055.112 represents a remanufactured or new-build unit that includes all internal clutches, shafts, and valve bodies pre-assembled within the main casing. It sits directly between the engine bellhousing and the final drive, managing load shifts under full power without interrupting traction. For optimal structural integrity, this assembly is sealed using the 4657101082: TRANSMISSION HOUSING as the primary structural shell, which houses the rotating components and oil galleries.
Symptoms of Failure
- Delayed or harsh engagement: When the complete unit wears internally, operators notice a significant lag between shifting and actual gear engagement, often accompanied by a jarring clunk. This is a classic sign of worn clutch packs or degraded valve body seals within the 4657.055.112 assembly.
- Erratic shifting under load: The transmission may hunt between gears or fail to hold a selected ratio when pushing heavy loads. This points to internal hydraulic pressure loss, often linked to cracks in the 4657201166: HOUS.FRONT SECT or the 4657201170: HOUSING REAR PART.
- External oil seepage at case joints: Visible fluid leaks around the split lines of the main housing indicate gasket failure or stress fractures. The 4657298102: HOUSING REAR SECTION is a common leak point due to thermal cycling.
- Overheating and burnt fluid odor: Slipping clutches generate excessive heat, causing the transmission fluid to darken and smell burnt. This often precedes a total loss of drive if the complete unit is not replaced.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4657.055.112 |
| Assembly Type | Complete Powershift Unit (5 WG 210) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 510 mm |
| Overall Height | 580 mm |
| Primary Material | High-strength cast iron (housing) with steel alloy internals |
| OEM Reference | ZF 5 WG 210 |
| Torque Capacity (est.) | 1,200 Nm |
| Fluid Capacity | 22 liters (approx.) |
Compatibility
This complete unit is specifically engineered for the ZF WG 210 Series of powershift transmissions. It is directly compatible with models including the WG180, WG200, and WG210 variants commonly found in wheel loaders, forklifts, and telehandlers from manufacturers such as Caterpillar, JCB, and Volvo. The 4657.055.112 assembly is a direct replacement for earlier 5-speed units and can be adapted to certain WG150 applications with minor modifications to the bellhousing interface. Always verify the serial number of your existing transmission against the ZF parts catalog to ensure a perfect fit.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Primary structural casing for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing input shaft and pump drive |
| 4657201170 | HOUSING REAR PART | Rear section enclosing output shaft and parking brake |
| 4657298102 | HOUSING REAR SECTION | End cap covering rear bearing and seal assembly |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for precise housing mating |
| 0636100801 | CAP SCREW | High-tensile bolt for housing fastening |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit protection |
| 4657301033 | SCREEN SHEET | Secondary filter screen for hydraulic control |
| 0636100803 | CAP SCREW | Bolt for securing rear housing section |
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