Overview
The ZF 4681.054.027 4 BP 210 BASICPOWER Transmission Assembly represents a complete, ready-to-install unit engineered for heavy-duty commercial and industrial driveline applications. This assembly integrates the planetary gear set, valve body, and hydraulic control module into a single, pre-assembled package, serving as the core power transfer component within the BP 210 and BP 230 series transmissions. Designed for vehicles requiring robust torque handling and reliable shifting under continuous load, the SKU 4681.054.027 replaces worn or failed assemblies to restore original equipment performance. Its construction utilizes high-strength alloy housings and precision-ground gears to withstand extreme operational stresses, making it a critical upgrade for fleet maintenance or rebuild projects.
Symptoms of Failure
When the ZF 4681.054.027 assembly begins to degrade, operators typically encounter these distinct failure indicators:
- Delayed or harsh gear engagement – A noticeable lag when shifting from neutral to drive or reverse, often accompanied by a jarring clunk, indicates internal clutch pack or valve body wear.
- Torque converter shudder at low speeds – A vibration or shuddering sensation during initial acceleration, especially under load, signals deteriorating friction materials or hydraulic pressure loss within the assembly.
- External fluid seepage near the bell housing – Oil leaks originating from the pump seal or gasket interfaces of the assembly, leaving puddles under the vehicle, are a common sign of housing fatigue or seal degradation.
- Erratic shifting under moderate throttle – The transmission may unexpectedly upshift or downshift without driver input, or fail to hold a gear, pointing to worn valve body components or solenoid failures within the unit.
Technical Specifications
| Specification | Detail |
|---|---|
| Part Number / SKU | 4681.054.027 |
| Assembly Type | Complete Transmission Assembly (4 BP 210 BASICPOWER) |
| Overall Length (approx.) | 780 mm (30.7 in) |
| Dry Weight (approx.) | 185 kg (408 lbs) |
| Housing Material | High-tensile cast aluminum alloy |
| Gear Material | Case-hardened alloy steel (20MnCr5 equivalent) |
| OEM Reference | ZF Friedrichshafen AG – BP 210 Series |
| Torque Capacity (estimated) | 2,100 Nm (1,549 lb-ft) |
| Fluid Capacity (approx.) | 18.5 liters (4.9 US gal) |
Compatibility
This assembly is specifically engineered for integration into ZF transmission models that share the BP 210 and BP 230 architecture. Verified compatible transmission families include:
- ZF WG180 – All variants using the 4 BP 210 gearset configuration.
- ZF WG200 – Models requiring the BASICPOWER hydraulic control system.
- ZF 4 HP 210 – Earlier generation units retrofitted with the BP 210 upgrade.
- ZF 4 BP 230 – Direct fit for 230 series assemblies with identical mounting interfaces.
Always cross-reference your existing transmission’s serial number and housing casting marks with the 4681.054.027 to confirm fitment before installation. For non-standard applications, consult your vehicle’s original equipment manufacturer (OEM) documentation.
