Make:
Allison Transmission
Model Variants:
4000, 4000 MH, 4000 HS, 4000 R, 4000 EVS, 4000 OFS
Production Years Covered:
1999 to present (4th and 5th Generation Controls)
Product Type:
Automatic transmission service repair manual (digital PDF)
Target Vehicles:
Heavy-duty trucks, buses, motorhomes, and off-highway equipment
Market Position:
Premium heavy-duty automatic transmission for commercial and specialty vehicles
Target Audience:
Fleet technicians, independent repair shops, and DIY owners
Key Features:
4th Generation Controls, optional PTO, output retarder, robust engineering
Competitive Advantage:
Known for reliability and advanced electronic control
Manual Purpose:
Provides comprehensive guidance for maintenance and repair
Manual Type:
Service Repair Factory Manual
Format:
PDF (digital download)
Delivery:
Instant download
Page Count:
N/A - not specified
Coverage Areas:
General operation, preventive maintenance, overhaul procedures, transmission disassembly, module rebuild, assembly
Illustrations:
Line drawings, cross-sectional views, exploded views
Transmission Mechanical:
Torque converter, planetary gear sets, clutches, shafts, bearings
Hydraulic System:
Pump, valve body, solenoids, hydraulic circuits
Electronic Controls:
4th Generation Controls, ECU, sensors, wiring
Cooling System:
Oil cooler and lines
Power Takeoff (PTO):
Optional PTO operation and repair
Output Retarder:
Optional retarder operation and repair
Diagnostic Trouble Codes:
Reading and clearing DTCs
Preventive Maintenance:
Fluid level checks, filter changes, inspections
Disassembly:
Step-by-step transmission disassembly
Module Rebuild:
Rebuild of valve body and control modules
Assembly:
Step-by-step assembly and torque specifications
Adjustments:
Linkage, sensor, and calibration adjustments
Testing:
Pressure tests and operational checks
Part Inspection:
Guidelines for inspecting components for wear and damage
Wear Limits:
Specified tolerances and wear limits for critical parts
Torque Specifications:
Fastener torque values
Clearances:
Critical clearances and end plays
Exploded Views:
Illustrated parts breakdowns
Part Numbers:
OEM part numbers for replacement components
Customer Service:
Contact information for technical support and parts
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Primary Engine:
Diesel engines from major manufacturers (Cummins, Detroit, Volvo, etc.)
Engine Options:
Various heavy-duty diesel engines with appropriate bell housing and flexplate
Maximum Torque:
Up to 1,200 lb-ft (depending on model and application)
Maximum Horsepower:
Up to 500 hp (typical)
Fuel System Interaction:
Controlled by engine ECU; transmission communicates via J1939 CAN bus
Type:
Automatic transmission, 6-speed
Standard Transmission:
Allison 4000 Series
Optional Transmission:
N/A - 4000 Series is the standard
Control System:
4th Generation Controls (electronic)
Features:
Optional PTO, output retarder, adaptive shift logic
Length:
Approximately 36 inches (varies by model)
Width:
Approximately 25 inches
Height:
Approximately 28 inches
Wheelbase:
N/A - transmission not wheelbase dependent
Curb Weight:
Approximately 750-850 lbs (dry, varies by model)
Fluid Capacity:
Approximately 6-8 quarts (pan dependent)
Electronic Stability Control:
No direct control, but interfaces with vehicle ESC
Traction Control:
Interfaces with vehicle system
Retarder:
Optional output retarder provides auxiliary braking
Crash Test Ratings:
N/A - not a vehicle
Fail-Safe Modes:
Limp-home mode and default gear strategies
Fluid Change:
Every 50,000 miles or 2 years (severe service: 25,000 miles or 1 year)
Filter Change:
With every fluid change
Inspections:
Regular checks for leaks and proper operation
Fluid Type:
TES 295 or Allison approved fluids
Fluid Capacity:
Varies by application; check dipstick or manual
Common Wear Items:
Clutch plates, seals, bearings, solenoids
Potential Issues:
Overheating, fluid leaks, electronic sensor failures
Manufacturer:
Allison Transmission (formerly Allison Division of General Motors)
Introduction:
Late 1990s as replacement for HT 700 series
Generations:
4th Generation Controls (early), 5th Generation Controls (later)
Production Location:
Indianapolis, Indiana, USA
