Overview
This ZF 4681.054.013 4 BP 210 BASICPOWER Transmission Assembly is a complete, factory-matched unit designed to restore full power flow and gear engagement in ZF’s BP 210 series. As a fully assembled drop-in replacement, it eliminates the need for piecemeal rebuilding. The SKU 4681.054.013 integrates the main gear cluster, clutch packs, and valve body into a single, pre-tested assembly. It sits at the heart of the driveline, converting engine torque into usable wheel speed. For a full rebuild, this assembly is often paired with a new TRANSMISSION HOUSING to ensure proper alignment and sealing of the entire unit.
Symptoms of Failure
- Delayed or harsh gear engagement: When the internal clutches and seals wear, you will notice a significant lag when shifting from Neutral to Drive or Reverse, often accompanied by a jarring clunk.
- Complete loss of forward or reverse drive: A worn assembly can cause total hydraulic pressure loss, resulting in the vehicle refusing to move despite the engine revving.
- Burning smell and dark fluid: Internal friction material shedding from the clutches contaminates the oil, producing a distinct burnt odor and turning the fluid a dark brown or black color.
- Erratic shifting or gear slippage: As the valve body and piston seals degrade, the transmission may slip out of gear under load or hunt randomly between gears during operation.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number | 4681.054.013 |
| Series | BP 210 BASICPOWER |
| Assembly Type | Complete Transmission Unit (4-speed) |
| Estimated Dry Weight | 195 kg (430 lbs) |
| Primary Material | Cast Aluminum Housing with Steel Gears |
| OEM Reference | ZF 4 BP 210 |
| Torque Capacity | Approx. 210 Nm |
Compatibility
This assembly is specifically engineered for the ZF BP 210 series. It is the primary power pack for the WG180 and WG200 transmission models commonly found in industrial forklifts, telehandlers, and small wheel loaders. The unit also directly replaces assemblies in the 4 BP 210 variant used in airport ground support equipment. When installing, ensure the HOUS.FRONT SECT and the HOUSING REAR PART are free of cracks to guarantee a proper seal. The CASE must also be inspected for wear at the bearing journals before final assembly.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4681101002 | TRANSMISSION HOUSING | Main structural casing for the gear train |
| 4681201007 | HOUS.FRONT SECT | Front section housing the input shaft and pump |
| 4681201008 | HOUSING REAR PART | Rear section supporting the output shaft |
| 4681298001 | CASE | Internal carrier for planetary gear sets |
| 0631306074 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | Fastener for securing the valve body cover |
| 4681301015 | FIXING PLATE | Retaining plate for clutch pack springs |
| 4681301016 | SCREEN SHEET | Fine mesh filter for the oil sump pickup |
| 4681301017 | SCREEN SHEET | Secondary filter screen for the cooler return line |
| 0636100803 | CAP SCREW | Fastener for the rear housing mounting flange |
Frequently Asked Questions
Q: Does the 4681.054.013 assembly include the torque converter?
A: No, this is a complete transmission assembly (gears, clutches, and valve body) but does not include the torque converter. The torque converter must be ordered separately based on your engine flywheel housing pattern.
Q: Can I install this unit without replacing the housing?
A: While it is possible, we strongly recommend inspecting the TRANSMISSION HOUSING for warpage or cracks. A damaged housing will misalign the new assembly and cause premature failure.
Q: What is the typical lifespan of this assembly in a forklift application?
A: With proper maintenance and clean oil, this unit typically lasts 5,000 to 8,000 operating hours. Harsh loading or neglected fluid changes will significantly reduce this lifespan.
📞 Need this part? Contact our ZF specialists:
Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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