Overview
The ZF 4681.024.004 4 BP 190 BASICPOWER Transmission Assembly represents a complete, factory-matched unit engineered for demanding industrial driveline applications. This assembly integrates the hydraulic control system, planetary gear sets, and clutch packs into a single, ready-to-install package. As a core component within the BP 190 series, it is designed to replace a worn or failed original assembly, restoring full power transfer efficiency. The SKU 4681.024.004 is a direct OEM-specification unit, ensuring seamless integration with existing mounting points and hydraulic circuits. It serves as the primary torque multiplication and gear reduction module, converting engine power into usable wheel or pump drive force.
Symptoms of Failure
When the ZF 4681.024.004 assembly begins to degrade, operators will notice distinct operational issues. Delayed or harsh engagement when shifting from neutral to drive or reverse is a primary indicator, often caused by worn clutch friction discs or degraded sealing rings. Intermittent gear slipping under load—where the transmission momentarily loses power during acceleration or climbing—signals internal hydraulic pressure loss or worn planetary bearings. External oil seepage from the main housing gasket or output shaft seal is common, leading to low fluid levels and eventual overheating. Finally, abnormal whining or grinding noises during operation, particularly in lower gears, suggest bearing fatigue or gear tooth damage within the assembly.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number / SKU | 4681.024.004 |
| Assembly Type | Complete Transmission Unit (4 BP 190 BASICPOWER) |
| Overall Length | Approx. 680 mm (26.8 in) |
| Dry Weight | Approx. 145 kg (320 lbs) |
| Housing Material | High-Strength Aluminum Alloy (A356-T6) |
| Input Torque Capacity | Up to 1,900 Nm (1,400 lb-ft) |
| Gear Ratio Range | 4.0:1 (First) to 0.75:1 (Overdrive) |
| OEM Reference | ZF 4681.024.004 / BP 190 Series |
| Fluid Capacity | Approx. 12 Liters (3.2 Gallons) |
Compatibility
This complete assembly is engineered for the ZF BASICPOWER BP 190 series and its direct derivatives. It is a direct fit for the following transmission models:
- ZF WG180 (all sub-variants using BP 190 internals)
- ZF WG200 (early production models with 4-speed configuration)
- ZF BP 190 (standard and high-torque versions)
- ZF BP 210 (when specified with 4 BP 190 BASICPOWER designation)
- ZF BP 230 (select models using the 4-speed BASICPOWER architecture)
Always verify the transmission model plate and current assembly part number before ordering. This unit replaces the older 4681.024.003 and is backward-compatible with most hydraulic control systems from 2015 onward.
