Overview
The ZF 4681.054.028 4 BP 210 BASICPOWER Transmission Assembly is a complete, factory-grade replacement unit designed for heavy-duty commercial vehicle applications. This assembly integrates the main housing, valve body, torque converter, and all internal rotating components into a single, ready-to-install package. As a core element of the ZF BASICPOWER series, it manages power distribution from the engine to the driveline, ensuring smooth gear engagement under high load conditions. The SKU 4681.054.028 specifically identifies the 4-speed configuration with a BP 210 torque rating, making it a direct drop-in solution for vehicles operating in construction, municipal, and long-haul environments.
Symptoms of Failure
When the ZF 4681.054.028 assembly begins to degrade, operators will notice distinct performance issues. Recognizing these signs early can prevent catastrophic drivetrain damage and costly downtime.
- Delayed or harsh gear engagement: A worn valve body or clutch pack within the assembly causes a noticeable lag when shifting from Neutral to Drive or Reverse, often accompanied by a jarring thud.
- Transmission fluid leaks at the bell housing: Deteriorating seals around the torque converter or pump drive allow ATF to seep out, leaving visible puddles under the vehicle and leading to low fluid levels.
- Intermittent gear slipping under load: As internal friction materials wear, the transmission may momentarily lose power delivery during uphill climbs or heavy acceleration, causing the engine to rev without corresponding vehicle speed.
- Overheating and burnt fluid odor: A failing torque converter or blocked cooler passages generate excessive heat, producing a distinct burnt smell from the dipstick or vent tube.
Technical Specifications
| Parameter | Value |
|---|---|
| Assembly Type | Complete Unit (4-Speed) |
| OEM Reference | ZF 4681.054.028 |
| Torque Rating | BP 210 (210 Nm / 155 lb-ft) |
| Dry Weight (approx.) | 68 kg (150 lbs) |
| Housing Material | Die-cast Aluminum Alloy |
| Overall Length | 620 mm |
| Fluid Capacity | 8.5 liters (ZF TE-ML 03 or 04) |
| Bolt Pattern | SAE 3 (Bell Housing) |
Compatibility
This complete assembly is engineered for the ZF BASICPOWER BP 210 and BP 230 series transmissions. It directly replaces units found in the following ZF model families:
- WG180 (4-speed variants with BP 210 rating)
- WG200 (early production models using the 4 BP configuration)
- HP 500 (when fitted with the BASICPOWER torque converter package)
- Ecomat 4 (specific retrofit applications requiring the 4681.054.028 housing)
Always verify the bell housing pattern and torque converter pilot diameter against your existing unit before installation. This assembly is not compatible with 5-speed or 6-speed ZF models without significant modification.
