Overview
The ZF 4657.085.005 5 WG 230 Powershift Transmission Assembly | Complete Unit is a fully integrated, factory-built drivetrain module designed for heavy-duty off-highway applications. This complete assembly serves as the central power distribution hub, combining a torque converter, multi-speed planetary gear set, and hydraulic clutch pack system within a single sealed housing. As a drop-in replacement for the WG 230 series, the SKU 4657.085.005 eliminates the need for piecemeal rebuilding, ensuring precise gear engagement and load-holding capability under extreme torque loads. The unit interfaces directly with the TRANSMISSION HOUSING and mates to the HOUS.FRONT SECT to form the primary structural backbone of the driveline.
Symptoms of Failure
- Delayed or harsh gear engagement: When the complete unit loses internal hydraulic pressure, operators experience a pronounced lag or jarring shift between forward and reverse ranges, often accompanied by a whining noise from the clutch packs.
- External oil seepage at housing joints: Cracks or warpage in the main casing cause transmission fluid to weep from the seam between the HOUSING REAR PART and the main body, leaving visible puddles under the vehicle after shutdown.
- Intermittent power loss under load: Worn internal splines or a failing torque converter stator allow the engine RPM to spike without corresponding wheel speed, particularly when climbing grades or pushing heavy material.
- Metallic grinding from the bell housing area: Debris from a failing bearing or gear tooth fracture within the assembly produces a distinct scraping sound that intensifies with throttle application.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number / SKU | 4657.085.005 |
| Assembly Type | Complete Powershift Transmission (5-Speed) |
| Dry Weight (approx.) | 385 kg (849 lbs) |
| Overall Length | 720 mm |
| Overall Width | 480 mm |
| Overall Height | 560 mm |
| Primary Material | High-Grade Cast Iron Housing with Steel Gears |
| OEM Reference | ZF WG 230 Series |
| Max Input Torque | 2,300 Nm |
| Hydraulic Pressure Range | 18–22 bar |
Compatibility
This complete unit is engineered for the ZF WG 230 transmission series and is directly interchangeable with earlier WG180 and WG200 variants that share the same bell housing bolt pattern and input shaft spline count. It is commonly found in loaders, graders, and industrial tractors from manufacturers such as Volvo, Caterpillar, and Case. The assembly also integrates with the HOUSING REAR SECTION to accommodate PTO-driven auxiliary equipment. Always verify the flywheel housing depth and torque converter stall speed before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101082 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing torque converter and pump |
| 4657201170 | HOUSING REAR PART | Rear casing enclosing output shaft and clutches |
| 4657298102 | HOUSING REAR SECTION | Extended rear section for PTO mounting |
| 0631306816 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | Fastener for housing-to-bell housing joint |
| 4656301148 | FIXING PLATE | Retainer plate for clutch pack preload |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Coarse mesh pre-filter for sump pickup |
| 0636100803 | CAP SCREW | High-tensile bolt for rear housing attachment |
