Overview
The ZF 4681.086.008 6 BP 230 BASICPOWER Transmission Assembly represents a complete, ready-to-install unit engineered for demanding industrial driveline applications. This fully assembled component integrates the planetary gear set, hydraulic control system, and output shaft into a single, pre-tested package. As a direct replacement for the BP 210 and BP 230 series transmissions, the SKU 4681.086.008 eliminates the need for piecemeal repairs, offering a turnkey solution for restoring full power transfer efficiency in heavy-duty machinery. Designed to handle continuous torque loads, this assembly ensures seamless engagement across all six forward gears, reducing downtime in material handling and construction equipment.
Symptoms of Failure
When the ZF 4681.086.008 assembly begins to degrade, operators typically notice distinct performance issues. Recognizing these signs early can prevent catastrophic driveline damage:
- Delayed or harsh gear engagement: A noticeable lag when shifting from neutral to drive, often accompanied by a jarring clunk, indicates internal clutch pack wear within the assembly.
- Progressive oil seepage at the bell housing: Fluid accumulation around the transmission-to-engine interface points to failing seals or gaskets, a common failure mode in high-cycle BP 230 units.
- Intermittent power loss under load: The transmission may slip or lose torque during uphill travel or when lifting heavy loads, signaling worn planetary gears or a failing torque converter stator.
- Unusual whining or grinding noises: A high-pitched whine that intensifies with speed, or a low grinding sound during deceleration, often points to bearing fatigue or gear tooth pitting inside the assembly.
Technical Specifications
| Specification | Value |
|---|---|
| Part Number / SKU | 4681.086.008 |
| Assembly Type | Complete Transmission Unit (6 BP 230 BASICPOWER) |
| Overall Length | 620 mm (24.4 in) |
| Dry Weight | 185 kg (408 lbs) |
| Housing Material | High-strength aluminum alloy (A356-T6) |
| Input Torque Capacity | 1,200 Nm (885 lb-ft) |
| Gear Ratios (1st–6th) | 5.60 / 3.40 / 2.20 / 1.50 / 1.00 / 0.75 |
| OEM Reference | ZF 4681.086.008 (Direct OE Replacement) |
| Fluid Capacity | 12.5 liters (3.3 gal) of ZF TE-ML 03 spec oil |
Compatibility
This complete assembly is engineered for the ZF BP 210 and ZF BP 230 series transmissions, which are widely deployed in industrial vehicles. It is a direct fit for the following transmission models and their variants:
- ZF WG180 – Common in 6–8 ton forklifts and telehandlers.
- ZF WG200 – Used in medium-duty wheel loaders and backhoe loaders.
- ZF 4WG-210 – Found in older generation construction equipment requiring a 6-speed upgrade.
- ZF 6 BP 230 BASICPOWER – The native model for this assembly, utilized in reach stackers and heavy terminal tractors.
Always verify the bell housing pattern and input shaft spline count (typically 14-tooth, 2-inch diameter) against your existing unit before installation. For applications outside the listed models, consult the original equipment manufacturer’s cross-reference guide.
