Overview
The ZF 4681.084.028 4 BP 230 BASICPOWER Transmission Assembly is a complete, factory-grade replacement unit engineered for medium-duty commercial and industrial drivetrains. This assembly integrates the main housing, valve body, torque converter, and clutch packs into a single, ready-to-install package. As a core component of the BP 230 Series, it serves as the primary power transfer module, converting engine torque into controlled wheel or PTO output. The SKU 4681.084.028 is specifically calibrated for the BASICPOWER variant, offering a balance of durability and operational simplicity for applications such as municipal trucks, construction loaders, and agricultural spreaders. This complete unit eliminates the need for core rebuilding, providing a direct swap solution that restores factory shift quality and load-holding capacity.
Symptoms of Failure
When the ZF 4681.084.028 assembly begins to degrade, operators typically notice three distinct failure modes. First, delayed or harsh engagement between forward and reverse gears becomes apparent, often accompanied by a pronounced clunk when shifting from neutral to drive. Second, internal hydraulic leakage manifests as erratic shift timing or a gradual loss of forward motion under moderate load, particularly when climbing grades. Third, torque converter shudder occurs during low-speed maneuvering, felt as a vibration through the chassis that worsens as transmission fluid temperature rises. Finally, visible fluid seepage from the bell housing or output seal area indicates worn internal seals, which can lead to low fluid levels and eventual gear slipping if left unaddressed.
Technical Specifications
| Part Number | 4681.084.028 |
| Assembly Type | Complete Transmission Unit (4-speed, BASICPOWER) |
| Dry Weight | Approx. 145 kg (320 lbs) |
| Overall Length | 685 mm (27.0 in) |
| Housing Material | High-strength aluminum alloy (A356-T6) |
| Torque Converter Diameter | 310 mm (12.2 in) |
| OEM Reference | ZF 4681.084.028 (Direct replacement) |
| Fluid Capacity | 12.5 liters (3.3 US gal) – ZF TE-ML 03 |
Compatibility
This complete unit is designed for the ZF BP 230 Series and its predecessor, the BP 210 Series. It directly replaces assemblies in the following transmission model families:
- ZF WG180 (4-speed variants with BASICPOWER logic)
- ZF WG200 (all non-overdrive versions)
- ZF 4 BP 210 (early production units requiring upgrade)
- ZF 4 BP 230 (standard and BASICPOWER configurations)
While the 4681.084.028 is a drop-in fit for most BP 230 applications, always verify bell housing bolt pattern and PTO mounting orientation against your original unit. For ZF WG180 models built after 2015, a minor software update to the transmission control unit may be required to fully utilize the BASICPOWER shift characteristics.
Installation Notes
This assembly ships with a pre-filled torque converter and requires only final fluid top-off after installation. Ensure the transmission cooler lines are flushed before connecting to prevent cross-contamination from debris in the old unit.
