Overview
The ZF 4681.054.007 4 BP 210 BASICPOWER Transmission Assembly is a complete, factory-matched unit designed for heavy-duty commercial and off-highway applications. This assembly integrates the core gear train, clutch packs, and hydraulic control system into a single, ready-to-install package. As a direct replacement for the BP 210 series, it restores full power flow and shift quality in ZF transmissions that have suffered catastrophic internal failure. The SKU 4681.054.007 ensures you receive the exact OEM-specification unit, eliminating guesswork during rebuilds. This assembly works in concert with the TRANSMISSION HOUSING to provide structural integrity and oil containment.
Symptoms of Failure
When the ZF 4681.054.007 assembly begins to fail, operators typically notice these specific warning signs:
- Delayed or harsh engagement — A noticeable lag when shifting from Neutral to Drive or Reverse, often accompanied by a loud clunk, indicates worn clutch packs or valve body degradation within the assembly.
- Intermittent gear slipping under load — The transmission may momentarily lose power delivery during uphill climbs or heavy hauling, a classic symptom of hydraulic pressure loss or worn friction discs.
- Chronic fluid overheating — If the transmission runs consistently hotter than normal (above 200°F/93°C), internal leakage or damaged torque converter components inside the assembly are likely culprits.
- Metallic debris in the oil pan — Finding bronze or steel particles during routine fluid changes points to bearing or gear wear within the assembly, requiring immediate replacement to avoid total seizure.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number | 4681.054.007 |
| Assembly Type | Complete BASICPOWER Unit (4 BP 210) |
| Dry Weight | Approx. 145 kg (320 lbs) |
| Housing Material | High-strength cast aluminum alloy |
| Overall Length | 610 mm (24.0 in) |
| Overall Width | 480 mm (18.9 in) |
| Overall Height | 420 mm (16.5 in) |
| OEM Reference | ZF 4681.054.007 |
| Bolt Torque (Main Case) | 80 Nm (59 ft-lbs) |
| Fluid Capacity (Assembly) | 12.5 liters (13.2 quarts) |
Compatibility
This complete assembly is engineered for the ZF BP 210 series, but it also directly replaces units in several other ZF model families. Verified compatible transmissions include the WG180, WG200, WG210, and Ecomat 4 HP 220 series when used with the correct bellhousing adapter. The assembly mates precisely with the HOUS.FRONT SECT and the HOUSING REAR PART to form a sealed driveline. For vehicles requiring a split-case design, the HOUSING REAR SECTION is also a direct fit. Always verify your transmission model tag before ordering.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural case for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing for torque converter and pump |
| 4657201168 | HOUSING REAR PART | Rear case section for output shaft and bearing support |
| 4657298101 | HOUSING REAR SECTION | Alternate rear housing for extended tail configurations |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for precise housing mating |
| 0636100801 | CAP SCREW | M10 fastener for housing bolt-up |
| 4656301148 | FIXING PLATE | Retains valve body and oil filter assembly |
| 4657301032 | SCREEN SHEET | Fine mesh filter for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Secondary filter screen for oil return line |
| 0636100803 | CAP SCREW | M12 cap screw for heavy-duty flange connections |
Frequently Asked Questions
Q: Is the ZF 4681.054.007 assembly pre-filled with oil?
A: No, this unit is shipped dry. You must fill it with the correct ZF-approved transmission fluid (e.g., ZF LifeguardFluid 8) to the proper level after installation. Refer to your vehicle’s service manual for the exact fill procedure.
Q: Can I install this assembly without replacing the torque converter?
A: ZF strongly recommends replacing the torque converter whenever a complete assembly is installed. Contaminated converter internals can quickly damage a new unit. Always inspect and replace the converter if there is any sign of wear or debris.
Q: What is the warranty period for this complete assembly?
A: Warranty terms vary by supplier, but most OEM-grade units carry a 12-month or 100,000-mile warranty against manufacturing defects. Verify with your distributor before purchase.
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Phone: +86 158 2286 3467 |
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