Overview
The ZF 4681.054.024 4 BP 210 BASICPOWER Transmission Assembly is a complete, ready-to-install unit engineered for medium-duty commercial and industrial drivetrains. As a fully assembled drop-in replacement, this part integrates the hydraulic control module, planetary gear sets, and torque converter housing into a single sealed assembly. The SKU 4681.054.024 is specifically configured for the BP 210 and BP 230 series, providing a direct OEM-specification upgrade for vehicles operating under continuous load conditions. This assembly eliminates the need for piecemeal component rebuilding, reducing downtime and ensuring consistent gear engagement across all forward and reverse ranges.
Symptoms of Failure
When the ZF 4681.054.024 assembly begins to degrade, operators typically notice three distinct failure modes. First, delayed engagement or harsh shifting between 2nd and 3rd gear occurs, often accompanied by a metallic grinding noise during cold starts. Second, external oil seepage from the bell housing mating surface or the output shaft seal becomes visible, leaving puddles under the vehicle after extended operation. Third, intermittent gear slipping under load—particularly when climbing grades or towing—manifests as a sudden RPM flare without corresponding acceleration. A fourth symptom, erratic electronic response from the integrated solenoid pack, can trigger a transmission control unit fault code, leading to a limp-home mode activation.
Technical Specifications
| Parameter | Specification |
|---|---|
| OEM Part Number | 4681.054.024 |
| Series Designation | 4 BP 210 BASICPOWER |
| Assembly Type | Complete Unit (Torque Converter + Gearbox) |
| Dry Weight | 98.5 kg (217 lbs) |
| Overall Length | 685 mm |
| Bell Housing Diameter | SAE 3 (305 mm) |
| Input Torque Capacity | 850 Nm (627 lb-ft) |
| Housing Material | Aluminum Alloy (A356-T6) |
| Fluid Capacity | 14.5 liters (ZF LifeguardFluid 8) |
| Bolt Pattern | 6-bolt, 180 mm PCD |
Compatibility
This assembly is engineered for the ZF BP 210 and ZF BP 230 transmission series, which are commonly found in municipal buses, refuse trucks, and mid-range construction loaders. It directly replaces units in the WG180 and WG200 model families when fitted with the appropriate adapter plate. Specific vehicle applications include the Mercedes-Benz Atego (2006-2012), MAN TGL series, and Iveco Eurocargo models equipped with ZF 6-speed automatic drivelines. The assembly is also backward-compatible with earlier ZF 4HP22 installations after a control module flash update. Always verify the transmission control unit software revision before installation to ensure proper shift mapping.
Additional Notes
- Requires ZF LifeguardFluid 8 or equivalent synthetic ATF.
- Torque converter stall speed: 1,950 RPM ± 50 RPM.
- Includes pre-installed speed sensor and wiring harness pigtail.
