Overview
The ZF 4657.085.001 5 WG 230 Powershift Transmission Assembly | Complete Unit is a fully integrated, factory-assembled gearbox core designed for heavy-duty off-highway machinery. This complete unit serves as the primary power transfer module within the WG 230 series, managing torque distribution across five forward speeds. The SKU 4657.085.001 represents a direct replacement assembly that eliminates the need for piecemeal rebuilding, ensuring precise clutch pack alignment and hydraulic circuit integrity. This assembly integrates directly with the 4657101082: TRANSMISSION HOUSING to form the structural backbone of the drivetrain.
Symptoms of Failure
- Delayed engagement or gear slipping under load: When the complete unit wears, internal clutch packs lose hydraulic pressure, causing hesitation when shifting from neutral to drive or slipping during heavy excavation.
- External oil leaks at mating surfaces: Cracks or warpage in the assembly housing lead to fluid seepage around the 4657201166: HOUS.FRONT SECT interface, leaving puddles under the vehicle.
- Abnormal grinding or whining noises: Worn bearings or planetary gear damage inside the assembly produce metallic sounds that intensify with engine RPM, indicating imminent internal failure.
- Erratic shifting or transmission overheating: Contaminated hydraulic fluid from internal debris causes valve body sticking, leading to harsh shifts and elevated operating temperatures.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number | 4657.085.001 |
| Assembly Type | Complete Powershift Unit (5 WG 230) |
| 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 4657.085.001 |
| Bolt Torque (Main Housing) | 120 Nm (using 0636100801: CAP SCREW) |
| Oil Capacity | 22 liters (SAE 10W-30) |
Compatibility
This complete unit is engineered specifically for the ZF WG 230 transmission series. It is also backward-compatible with earlier WG 180 and WG 200 models when used with the correct 4657201170: HOUSING REAR PART adapter. The assembly fits ZF 5 WG 230 variants found in Case IH, New Holland, and JCB telehandlers and wheel loaders. For proper sealing, ensure the 4657298102: HOUSING REAR SECTION is inspected for wear during installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural casing for gear train |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft |
| 4657201170 | HOUSING REAR PART | Rear casing for output shaft support |
| 4657298102 | HOUSING REAR SECTION | End cover for hydraulic valve access |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing assembly |
| 0636100801 | CAP SCREW | M16 bolt for housing fastening |
| 4656301148 | FIXING PLATE | Locking plate for bearing retention |
| 4657301032 | SCREEN SHEET | Fine mesh filter for oil pickup |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for return line |
| 0636100803 | CAP SCREW | M12 bolt for valve body mounting |
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