Overview
This ZF 4681.054.012 4 BP 210 BASICPOWER Transmission Assembly is a complete, factory-matched unit designed for heavy-duty industrial drivelines. As a core assembly within the BP 210 Series, it integrates the main gear cluster, clutch packs, and hydraulic control system into a single, ready-to-install package. The SKU 4681.054.012 serves as the primary power transfer module, converting engine torque into usable wheel speed. This assembly is typically mounted between the engine bellhousing and the final drive, and it is often paired with a TRANSMISSION HOUSING to ensure proper alignment and structural integrity. When replacing a worn unit, technicians frequently also inspect the HOUS.FRONT SECT for cracks or wear patterns that could affect oil flow.
Symptoms of Failure
When the ZF 4681.054.012 assembly begins to degrade, operators often notice specific performance issues. Look for these common failure indicators:
- Delayed or harsh gear engagement: A worn assembly may cause a noticeable lag when shifting from Neutral to Drive or Reverse, often accompanied by a clunking sound.
- Torque converter shudder under load: If the internal clutch packs are slipping, you may feel a vibration or shudder when accelerating from a stop or climbing a grade.
- External oil seepage at the main case seam: Leaks often develop where the front and rear sections join, requiring inspection of the HOUSING REAR PART for warpage or gasket failure.
- Erratic shifting or loss of forward gears: Internal wear can cause the transmission to slip out of gear or fail to engage specific ranges, indicating the need for a complete assembly replacement.
Technical Specifications
| Specification | Value |
|---|---|
| Part Number / SKU | 4681.054.012 |
| Assembly Type | Complete Unit (4 BP 210 BASICPOWER) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | Cast Iron / Aluminum Composite |
| Overall Length (approx.) | 720 mm |
| OEM Reference | ZF BP 210 Series |
| Related Fastener | CAP SCREW (M12 x 1.5) |
| Related Pin | CYLINDRICAL PIN |
| Mounting Plate | FIXING PLATE |
Compatibility
This complete assembly is engineered for the ZF BP 210 Series, specifically the 4-speed BASICPOWER variant. It is commonly found in the following ZF transmission models and their derivatives:
- ZF WG180
- ZF WG200
- ZF BP 210 (all sub-variants)
- ZF 4 BP 210
During installation, always verify the condition of the CASE for stress fractures, and ensure the SCREEN SHEET (Part 4681301016) is clean to prevent debris from entering the valve body.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4681101002 | TRANSMISSION HOUSING | Main structural case for gear and shaft support |
| 4681201007 | HOUS.FRONT SECT | Front section housing the pump and torque converter |
| 4681201008 | HOUSING REAR PART | Rear section containing output shaft and parking pawl |
| 4681298001 | CASE | Enclosure for valve body and clutch packs |
| 0631306074 | CYLINDRICAL PIN | Alignment dowel for housing mating surfaces |
| 0636100801 | CAP SCREW | Fastener for securing housing sections |
| 4681301015 | FIXING PLATE | Retainer plate for clutch piston assembly |
| 4681301016 | SCREEN SHEET | Fine mesh filter for hydraulic fluid |
| 4681301017 | SCREEN SHEET | Secondary coarse mesh filter |
| 0636100803 | CAP SCREW | Bolt for valve body attachment |
Frequently Asked Questions
Q: Can the ZF 4681.054.012 assembly be rebuilt, or must it be replaced as a complete unit?
A: While individual internal components like clutch discs and seals are available, the 4681.054.012 is sold as a complete, pre-assembled unit to ensure proper clearances and hydraulic balance. Rebuilding is possible but requires specialized tooling and knowledge of the BP 210 series.
Q: What is the typical lifespan of this transmission assembly under normal industrial use?
A: With proper maintenance and clean fluid, the ZF 4 BP 210 BASICPOWER assembly can last 8,000 to 12,000 operating hours. Heavy loading or frequent start-stop cycles may reduce this interval.
Q: Are the CAP SCREWS (0636100801) included with the assembly?
A: No, the assembly is supplied without fasteners. We recommend ordering the CAP SCREW and CYLINDRICAL PIN separately to ensure correct torque specifications are met during installation.
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Email: info@partszf.com |
Phone: +86 158 2286 3467 |
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