Overview
The ZF 4681.024.003 4 BP 190 BASICPOWER Transmission Assembly | Complete Unit is a fully integrated drop-in replacement designed for medium-duty ZF powershift transmissions. This complete assembly, referenced under SKU 4681.024.003, serves as the primary torque-converter and gear train housing for the BP 190 series. It integrates the forward clutch pack, planetary gear set, and output shaft within a single sealed unit. As a direct OEM-spec component, it eliminates the need for core rebuilding and ensures immediate restoration of driveline integrity in construction and agricultural machinery.
Symptoms of Failure
When the ZF 4681.024.003 assembly begins to degrade, operators will notice distinct operational anomalies. Common failure indicators include:
- Delayed engagement or gear slipping under load: The unit may hesitate before moving forward or reverse, particularly when climbing grades or carrying heavy payloads.
- Internal hydraulic pressure loss: A gradual drop in line pressure leads to soft shifts and eventual clutch pack burn, often accompanied by a burnt transmission fluid odor.
- External oil seepage from the bell housing seam: Worn gaskets or housing cracks cause fluid to weep from the joint between the converter and main case, leaving visible drips on the undercarriage.
- Unusual whining or grinding noises: Damaged planetary bearings or worn gear teeth produce a metallic sound that increases with engine RPM, indicating imminent internal failure.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number / SKU | 4681.024.003 |
| Assembly Type | Complete Transmission Unit (BP 190 BASICPOWER) |
| Overall Length | ~ 620 mm (24.4 in) |
| Dry Weight | ~ 145 kg (320 lbs) |
| Housing Material | High-strength cast iron (GGG-40) |
| Torque Converter Diameter | 340 mm |
| Max Input Torque | 900 Nm (664 lb-ft) |
| OEM Reference | ZF 4681.024.003 / BP 190 Series |
| Fluid Capacity | 12.5 liters (3.3 US gal) |
Compatibility
This complete assembly is engineered for the ZF BP 190 transmission family and shares mounting patterns with the BP 210 and BP 230 series. It is a direct fit for the following ZF models:
- ZF WG180 (early production variants with BP 190 bell housing)
- ZF WG200 (when retrofitted with BP 190 torque converter)
- ZF BP 210 Series (all sub-variants using 4-speed powershift)
- ZF BP 230 Series (units requiring 340mm converter interface)
- ZF 4 BP 190 (BASICPOWER and standard power versions)
Always verify the input shaft spline count and bell housing bolt pattern against your existing unit before installation. This assembly is not compatible with the older WG 150 or WG 120 series without adapter plates.
