Allison 4000 Product Family Transmission Parts Catalog PC2456EN – 2005 PDF Download

Description

Allison 4000 Product Family Transmission Parts Catalog PC2456EN

This is the complete Allison Transmission 4000 Product Family Parts Catalog, publication PC2456EN, dated April 2005. It covers the full range of 4000 Series vocational and highway models — from the 4000 EVS and 4500 EVS through the 4700 RDS, 4800 SP, B 500, and the HD 4060, HD 4560, HD 4070, HD 4076, T 425, and T 450 variants. Every assembly, subassembly, and detail part for these transmissions is cataloged here with the exact Allison part number and group reference needed to order correctly.

File Details

• Manual Type: Parts Catalog
• Brand: Allison Transmission (General Motors Corporation)
• Model: 4000 Product Family
• Document Number: PC2456EN
• Edition: April 1, 2005
• Language: English
• Page Count: 892
• File Format: PDF

Chapters Covered

The catalog is divided into numbered sections, each covering a specific area of the transmission. The Sectional Index makes it easy to jump to the right group.

• Pictorial Index
• Service Kits
• Assembly Number (A/N) Table
• Main Housing — Section 01
• Fill Tube — Section 02
• Main Shaft — Section 05
• Flange — Section 08
• Front Support And Oil Pump — Section 10
• P1 Planetary — Section 14
• P2 Planetary — Section 15
• Control Valve — Section 16
• Oil Cooler — Section 20
• Torque Converter — Section 21
• Flexplate And Adapter — Section 24
• Rotating Clutch — Section 25
• Retarder Accumulator — Section 30
• PTO Provision — Section 31
• Converter Housing — Section 34
• Retarder Controls — Section 35
• P3 Planetary And Rear Cover/Retarder — Section 39
• Wiring Harnesses And Specifications — Section 70
• Throttle Position Sensor (TPS) — Section 71
• Electronic Control Unit (ECU)/Shift Selectors — Section 72
• Vehicle Interface Module (VIM) — Section 73
• Service Information Letters
• Numerical Index
• Foldouts (Cross-Sectional Views)

Pictorial Index and How-To-Use Guide

The first 20 pages walk you through the catalog structure, show you how to read the assembly number from the transmission nameplate, and explain the group numbering system. The pictorial index uses exploded transmission views to point you to the right section before you dive into a parts list.

Main Housing, Fill Tube, and Main Shaft (Sections 01, 02, 05)

These sections break down the main case, the fill tube assembly, and the main shaft for both close-ratio and wide-ratio configurations. You’ll find exploded views with every bolt, O-ring, retaining ring, and bearing called out by reference number and part number.

Flange, Front Support, and Oil Pump (Sections 08, 10)

The flange section covers output yokes and flanges for a wide range of driveline configurations — 1710, 1810, 1760, SPL170, SPL250, and more, including half-round and full-round styles. The front support and oil pump section covers the charging pump, ground sleeve, and front bearing retainer.

P1 and P2 Planetary Gear Sets (Sections 14, 15)

Complete exploded views of the P1 and P2 planetary assemblies, with carriers, pinion gears, spindles, thrust washers, bearings, and retaining rings. The catalog lists service kits where parts are only sold as assemblies, and marks parts that are not serviced individually.

Control Valve Assembly (Section 16)

The largest and most detailed section. It covers the full control valve body for multiple generations of WTEC controls, including the WTEC II and WTEC III configurations, with all solenoid assemblies, valve bodies, springs, plugs, separator plates, gaskets, and internal wiring harnesses. The group listings change by transmission serial number and TID (TransID) level, so you order the exact parts for your unit.

Oil Cooler, Torque Converter, and Rotating Clutch (Sections 20, 21, 25)

Oil cooler options cover remote mount and direct mount configurations, with and without retarder. The torque converter section includes the converter pump, turbine, stator, lockup piston, damper, and all bearings and seals for the TC 521, TC 531, TC 541, TC 551, and TC 561 series. The rotating clutch section details the C1 and C2 clutch assemblies, including pistons, plates, hubs, and return springs.

Flexplate and Adapter (Section 24)

Covers the flexplate and adapter assemblies for a wide range of engine makes: Caterpillar, Cummins, Detroit Diesel, Mack, Mercedes, Navistar, Volvo, Scania, and DAF. Each group identifies the correct flexplate, starter ring gear, adapter plate, and hardware for the engine-to-transmission interface.

Retarder Accumulator, PTO Provision, and Converter Housing (Sections 30, 31, 34)

The retarder accumulator section covers the air solenoid, cylinder body, piston, and seal kit for retarder-equipped models. PTO provision covers the drive gear, cover, gasket, and hardware for power take-off configurations. The converter housing section covers both PTO and non-PTO housings, including the seal assembly, bearing retainer, and speed sensor mounting.

Retarder Controls and P3 Planetary/Rear Cover (Sections 35, 39)

Retarder controls covers the lever, pedal, resistance modules, pressure switches, and wiring connectors for the retarder system. The P3 planetary and rear cover/retarder section is one of the most comprehensive in the catalog, covering close-ratio and wide-ratio configurations, low/medium/high torque retarders, tachograph provisions, and dropbox provisions. Every bearing, seal, gasket, and fastening detail is listed.

Wiring Harnesses, TPS, ECU/Shift Selectors, and VIM (Sections 70, 71, 72, 73)

These sections cover the electronic control system. You’ll find complete wiring harness part numbers and specifications (including harness lengths and connector types), throttle position sensor assemblies by mounting length, the WTEC II and WTEC III ECUs, pushbutton and lever shift selectors, and the Vehicle Interface Module. The catalog explains how to identify the correct ECU by calibration number and how to order replacement parts.

Service Kits and Service Information Letters

The service kits section lists master overhaul kits, seal and gasket kits, and special-purpose kits with every part number they contain. The Service Information Letters (SIL) section contains reprints of selected Allison service bulletins that affect parts ordering, including the retarder accumulator serviceability update (7-WT-96), sealring color coding (27-WT-96), and wiring harness service policy (1-WT-97).

Numerical Index and Foldouts

The numerical index lists every part number in the catalog with its figure and reference number, cross-referenced to show part number history — whether a part replaces an older part or has been replaced. The foldouts at the back give you full cross-sectional views of the transmission in standard, retarder, and PTO configurations.

Who This Parts Catalog Is For

This catalog is aimed at transmission rebuilders, fleet maintenance shops, and anyone who needs to order the right Allison part the first time. Whether you’re resealing a control valve, replacing a planetary carrier, or matching a flexplate to a specific engine, the PC2456EN catalog gives you the exact part number and group reference. You won’t find aftermarket guesses or generic listings — every part number here is the one Allison assigned to that component.

Why It Matters

Allison 4000 Series transmissions are expensive, and the wrong part can cost you a day or more in downtime. This catalog eliminates that guesswork. It also shows the serial number breakpoints where parts changed, so you don’t order a new-style part for an early unit or an old-style part for a late one. The group listings tell you which parts are serviced only as assemblies, which are superseded, and which are no longer available — before you place an order.

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Instant PDF Delivery

This is a digital PDF download, not a printed book. After payment, you get immediate access to the full 892-page catalog. The file is printable on standard paper and readable on any computer, tablet, or smartphone. There’s no shipping wait, no lost package, and you can keep a copy on your shop computer and another in your service truck. Search the PDF for a part number or scroll through the section you need — the full catalog is in your hands the moment you check out.