Overview
The ZF 4681.054.009 4 BP 210 BASICPOWER Transmission Assembly is a complete, factory-matched unit designed for heavy-duty industrial drivelines. As the core power transfer module in the BP 210 series, this assembly integrates the planetary gear sets, clutch packs, and hydraulic control system into a single ready-to-install package. The SKU 4681.054.009 replaces worn or failed assemblies, restoring full torque capacity and shift quality in ZF off-highway transmissions. It sits centrally within the driveline, connecting the torque converter to the output shaft, and is engineered to handle continuous high-load applications in construction, mining, and agricultural machinery.
Symptoms of Failure
When the ZF 4681.054.009 assembly begins to fail, operators typically notice delayed or harsh gear engagement during acceleration, a clear sign of internal clutch wear. Another common symptom is erratic shifting or gear slipping under load, often accompanied by a burning smell from overheated friction material. External oil leaks around the main housing seam may also develop, indicating seal degradation within the assembly. Finally, unusual whining or grinding noises from the transmission center section suggest bearing or gear damage, requiring immediate replacement of the complete unit.
Technical Specifications
| Parameter | Specification |
|---|---|
| Part Number / SKU | 4681.054.009 |
| Assembly Type | Complete Transmission Unit (4 BP 210 BASICPOWER) |
| Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-strength cast iron |
| Overall Length | 620 mm |
| Max Input Torque | 2,100 Nm |
| OEM Reference | ZF 4681.054.009 / BP 210 Series |
| Related Housing Parts | 4657101078: TRANSMISSION HOUSING, 4657201166: HOUS.FRONT SECT, 4657201168: HOUSING REAR PART, 4657298101: HOUSING REAR SECTION |
Compatibility
This complete assembly is engineered for the ZF BP 210 series, specifically the 4 BP 210 BASICPOWER variant. It is directly compatible with ZF WG180, WG200, and WG210 transmission models used in wheel loaders, forklifts, and telehandlers. The unit also fits select ZF 4WG-200 and 4WG-210 drivelines where the BP 210 housing pattern is employed. For proper installation, ensure the TRANSMISSION HOUSING (4657101078) is in good condition, and verify alignment with the HOUS.FRONT SECT (4657201166) and HOUSING REAR PART (4657201168). The HOUSING REAR SECTION (4657298101) is also required for complete assembly in extended chassis configurations.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101078 | TRANSMISSION HOUSING | Main structural casing for gear and shaft support |
| 4657201166 | HOUS.FRONT SECT | Front section housing for input shaft and bearings |
| 4657201168 | HOUSING REAR PART | Rear housing section for output shaft support |
| 4657298101 | HOUSING REAR SECTION | Extended rear housing for additional gear stages |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for housing assembly |
| 0636100801 | CAP SCREW | Fastener for housing sections |
| 4656301148 | FIXING PLATE | Secures internal components to housing |
| 4657301032 | SCREEN SHEET | Filter screen for hydraulic circuit |
| 4657301033 | SCREEN SHEET | Secondary filter screen for oil return |
| 0636100803 | CAP SCREW | High-strength bolt for final assembly |
Frequently Asked Questions
Q: Can the ZF 4681.054.009 be installed without replacing the housing sections?
A: Yes, but only if the existing TRANSMISSION HOUSING and HOUS.FRONT SECT are free from cracks or warping. We recommend replacing them simultaneously to avoid misalignment.
Q: What is the typical lifespan of this complete assembly in a wheel loader?
A: With proper maintenance and clean oil, the 4681.054.009 unit typically lasts 8,000–12,000 operating hours before requiring overhaul.
Q: Does this assembly include the torque converter?
A: No, the 4 BP 210 BASICPOWER assembly includes only the gearbox internals and main housing. The torque converter is sold separately.
📞 Need this part? Contact our ZF specialists:
Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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