Overview
The ZF 4681.102.001 INPUT for BP210/BP230 is a critical OEM genuine component engineered to transfer rotational force from the torque converter directly into the planetary gear sets of ZF’s heavy-duty BP210 and BP230 transmissions. This input shaft assembly, identified by SKU 4681.102.001, sits at the front of the main gear case and interfaces directly with the TRANSMISSION HOUSING to ensure precise alignment and torque distribution. Designed for high-cycle industrial applications, this part withstands extreme torsional loads while maintaining smooth power flow. Its precision-ground splines and hardened steel construction guarantee a tight, backlash-free connection to the clutch packs, making it indispensable for maintaining driveline integrity in construction, mining, and municipal vehicles.
Symptoms of Failure
When the ZF 4681.102.001 INPUT begins to wear, operators typically notice three distinct failure modes. First, hard shifting or delayed engagement occurs as worn splines fail to mesh cleanly with the clutch hub, causing hesitation when moving from neutral to drive. Second, high-frequency vibration at cruising speeds indicates bearing surface degradation, often mistaken for driveline imbalance. Third, metallic debris in the transmission oil pan signals spalling on the input shaft’s hardened surface. If left unaddressed, these symptoms escalate into complete torque loss, requiring removal of the HOUS.FRONT SECT for full disassembly.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 4681.102.001 |
| Material | Case-hardened alloy steel (20MnCr5 equivalent) |
| Overall Length | 312 mm |
| Spline Diameter | 48 mm (24-tooth involute) |
| Weight | 4.7 kg |
| OEM Reference | ZF 4681.102.001 (Genuine) |
| Surface Hardness | 58-62 HRC |
| Max Torque Capacity | 2,100 Nm |
Compatibility
This genuine input shaft is engineered exclusively for the ZF BP210 and ZF BP230 series transmissions. It is also a direct replacement for units in the WG180, WG200, and WG210 families when fitted with the BP-style front housing. The part interfaces with the HOUSING REAR PART to create a sealed bearing cavity. Always verify that the CASE number matches your unit’s serial plate before installation. This input is not compatible with older ZF 4HP or 5HP series transmissions without significant adapter modifications.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4681101002 | TRANSMISSION HOUSING | Main structural case enclosing gear sets |
| 4681201007 | HOUS.FRONT SECT | Front section supporting input shaft bearing |
| 4681201008 | HOUSING REAR PART | Rear section housing output shaft assembly |
| 4681298001 | CASE | Complete transmission case assembly |
| 0631306074 | CYLINDRICAL PIN | Alignment pin for housing dowels |
| 0636100801 | CAP SCREW | M10 bolt for front housing retention |
| 4681301015 | FIXING PLATE | Locks input shaft bearing in place |
| 4681301016 | SCREEN SHEET | Fine mesh filter for oil return circuit |
| 4681301017 | SCREEN SHEET | Coarse mesh pre-filter for pump intake |
| 0636100803 | CAP SCREW | M12 bolt for rear housing attachment |
Frequently Asked Questions
Q: Can I install the ZF 4681.102.001 INPUT without removing the transmission from the vehicle?
A: No. This part requires removal of the transmission bellhousing and front cover. You must detach the HOUS.FRONT SECT to access the input shaft retaining ring. Plan for a full bench rebuild.
Q: How do I confirm this input shaft fits my BP210 serial number?
A: Check the 6th and 7th digits of your transmission serial number. If they read “21” or “23”, this part is compatible. Also verify that your CASE casting has the “BP” prefix stamped near the oil fill plug.
Q: What torque specification applies to the input shaft nut?
A: The retaining nut on the 4681.102.001 requires 280 Nm ± 10 Nm. Always use a new FIXING PLATE and stake it after torquing to prevent loosening under load.
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Phone: +86 158 2286 3467 |
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