Overview
The ZF 4657.056.102 6 WG 210 Powershift Transmission Assembly is a complete, factory-engineered unit designed for heavy-duty off-highway applications. As the core power transfer module in the WG 210 series, this assembly integrates the torque converter, planetary gear sets, and clutch packs into a single sealed housing. The SKU 4657.056.102 represents a direct OEM replacement that restores full hydraulic and mechanical function to ZF powershift transmissions. This unit sits between the engine flywheel and the driveline, managing gear ratio changes under load without interrupting power flow. For a complete rebuild, this assembly must be paired with a sound TRANSMISSION HOUSING to ensure proper alignment of all rotating components.
Symptoms of Failure
- Delayed or harsh gear engagement: When the internal clutch packs wear, operators experience a noticeable lag or jarring shift when moving from neutral to forward or reverse, indicating low hydraulic pressure within the assembly.
- Oil leaks at the bell housing interface: Worn seals or cracks in the main casing allow transmission fluid to escape, often pooling under the vehicle after extended operation. This is a common failure point requiring replacement of the HOUS.FRONT SECT.
- Gear slipping under load: The transmission may momentarily lose torque during uphill climbs or heavy pushing, accompanied by a high-pitched whine from the planetary gears. This signals worn friction discs or damaged splines inside the unit.
- Overheating and burnt fluid smell: Internal debris from failing bearings restricts oil flow, causing the transmission to run hot and emit a acrid odor. This often necessitates inspection of the HOUSING REAR PART for metal contamination.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4657.056.102 |
| Assembly Type | Complete Powershift Unit |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Overall Length | 620 mm |
| Overall Width | 480 mm |
| Overall Height | 510 mm |
| Housing Material | Cast Iron (GGG-40) |
| OEM Reference | ZF 6 WG 210 |
| Torque Capacity | 2,100 Nm (1,549 lb-ft) |
| Number of Speeds | 6 Forward / 1 Reverse |
Compatibility
This complete unit is engineered for the ZF WG 210 series of powershift transmissions. It is directly compatible with the following ZF models: WG 180, WG 200, WG 210, and WG 250 series. The assembly fits applications in wheel loaders, forklifts, and telescopic handlers from manufacturers such as Liebherr, JCB, and Manitou. For proper installation, ensure the HOUSING REAR SECTION is free of cracks and the mating surfaces are clean. This unit does not include the torque converter or electronic control module, which must be sourced separately.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing the torque converter bell |
| 4657201170 | HOUSING REAR PART | Rear casing containing output shaft bearings |
| 4657298102 | HOUSING REAR SECTION | Extended rear housing for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing doweling |
| 0636100801 | CAP SCREW | M16 bolt for housing flange fastening |
| 4656301148 | FIXING PLATE | Locks clutch pack retaining nuts |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump pickup |
| 0636100803 | CAP SCREW | M12 bolt for valve body attachment |
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