Overview
The ZF 4657.055.124 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 control system into a single, sealed assembly. As the central power transfer component in the WG 210 series, it converts engine torque into precise, multi-speed output for loaders, graders, and industrial vehicles. The SKU 4657.055.124 identifies this as a complete, factory-spec unit, ensuring direct replacement without the need for sub-assembly sourcing. When installing this unit, it is critical to verify the integrity of the surrounding structural components, such as the 4657101082: TRANSMISSION HOUSING, which provides the primary mounting and oil containment for the assembly.
Symptoms of Failure
When the ZF 4657.055.124 complete unit begins to fail, operators typically notice these specific performance issues:
- Erratic gear engagement or slipping under load: Worn clutch packs or valve body degradation cause the transmission to hesitate or lose torque during acceleration, especially in forward-reverse cycles.
- External oil leaks at housing seams: Cracks or gasket failure in the main casing lead to visible fluid loss, often pooling near the bell housing or rear output seal.
- Delayed or harsh shifting: Contaminated hydraulic fluid or a failing torque converter results in jarring gear changes, with a noticeable lag between shift commands.
- Overheating and burnt fluid odor: Internal friction from worn bearings or planetary gears generates excessive heat, producing a distinct burnt smell from the transmission breather.
Technical Specifications
| Parameter | Specification |
|---|---|
| Product Type | Complete Powershift Transmission Assembly |
| ZF Part Number | 4657.055.124 |
| Series | WG 210 |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | High-Grade Cast Iron (GGG-40) |
| OEM Reference | ZF 5 WG 210 |
| Torque Capacity (max) | 1,200 Nm |
| Number of Speeds | 5 Forward / 1 Reverse |
Compatibility
This complete unit is engineered for the ZF WG 210 series powershift transmissions. It is directly compatible with the following ZF models and their derivatives: WG 180, WG 200, WG 210, and WG 220. These transmissions are commonly found in articulated dump trucks, wheel loaders, and telescopic handlers from manufacturers such as Volvo, Case, and JCB. For a full rebuild, ensure the 4657201166: HOUS.FRONT SECT and the 4657201170: HOUSING REAR PART are inspected for wear. In some configurations, the 4657298102: HOUSING REAR SECTION is also required for specific output flange adaptations.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural casing for the gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for pump drive and input shaft |
| 4657201170 | HOUSING REAR PART | Rear section covering output planetary gears |
| 4657298102 | HOUSING REAR SECTION | Alternate rear housing for specific output configurations |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | Fastener for housing flange connections |
| 4656301148 | FIXING PLATE | Retainer plate for clutch pack assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic oil circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump return line |
| 0636100803 | CAP SCREW | High-tensile bolt for rear housing attachment |
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