Overview
The ZF 4657.055.116 5 WG 210 Powershift Transmission Assembly | Complete Unit is a fully integrated, factory-built gearbox core designed for heavy-duty off-highway machinery. This complete assembly serves as the central power distribution hub, managing torque flow from the engine through five forward speeds and one reverse. The SKU 4657.055.116 identifies a direct replacement unit that includes all internal clutches, shafts, and the main case structure. When installing this assembly, ensure the 4657101082: TRANSMISSION HOUSING is properly aligned to prevent misalignment stress on the main bearings.
Symptoms of Failure
- Delayed or harsh engagement: When the complete unit loses hydraulic pressure, operators experience a noticeable lag between shifting and gear engagement, often accompanied by a jarring clunk.
- Oil leaks at the rear seal: A worn assembly often weeps transmission fluid from the output shaft area, leaving puddles under the vehicle and indicating internal seal degradation.
- Intermittent gear slipping under load: As internal clutches wear, the transmission may momentarily lose power transfer when climbing grades or hauling heavy loads, a classic sign of failing friction discs within the 5 WG 210.
- Unusual whining or grinding noises: Metal-to-metal contact from worn bearings inside the assembly produces a high-pitched whine that increases with engine RPM, signaling imminent failure.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4657.055.116 |
| Assembly Type | Complete Powershift Unit (5 WG 210) |
| Overall Length | ~780 mm |
| Dry Weight | ~185 kg (408 lbs) |
| Main Housing Material | High-Grade Cast Iron (GGG-40) |
| OEM Reference | ZF 5 WG 210 Series |
| Bolt Torque (Main Case) | 120 Nm (M12 cap screws) |
Compatibility
This complete assembly is engineered for the ZF WG 210 Series powershift family. It is a direct fit for models including the WG180, WG200, and WG210 variants used in loaders, graders, and industrial tractors. The unit also integrates with earlier WG150 series applications when paired with the correct 4657201166: HOUS.FRONT SECT adapter. For rear-mounted equipment, the 4657201170: HOUSING REAR PART and 4657298102: HOUSING REAR SECTION must be verified for correct bolt pattern alignment.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural case for gear support |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201170 | HOUSING REAR PART | Rear case section for output bearings |
| 4657298102 | HOUSING REAR SECTION | Extended rear housing for PTO mount |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing dowels |
| 0636100801 | CAP SCREW | M12 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Locks bearing in position |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter |
| 0636100803 | CAP SCREW | M10 bolt for cover plates |
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