15-WT-05, Rev A.

pdf 11/7/05 10:57:06 AM

15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 1 of 38

SUBJECT: Allison 4th Generation Controls for 3000 and 4000 Product Families Transmissions

EQUIPMENT AFFECTED: All 3000 and 4000 Product Families Transmissions

SERIAL NUMBERS AFFECTED: S/N 6510586194

S/N 6520038485
S/N 6610171542
S/N 6620001001

Introduction
In July 2005, Allison Transmission released the Allison 4th Generation Control system for the 3000 and 4000 Product
C
Families transmissions. The purpose of this Service Information Letter (SIL) is to provide an overview of the new system
M and to provide serviceability information specific to the new generation of controls.
Y
During the period July 2005 to June 2006 all Original Equipment Manufacturers (OEMs) and Distributors specifying
CM Allison 3000 and 4000 Product Families products will transition from the current WTEC III controls to the new Allison
4th Generation Controls. After June 2006, Allison Transmission will no longer provide WTEC III components for new
vehicle installations unless they are common to both systems.
MY

CY

The Allison 4th Generation Control system incorporates recent advances in electronic controller technology. As a result,
the new control system provides Allison Transmission customers with new product features and shift quality
CMY

K
improvements. The primary components affected are:

1. Transmission Control Module (TCM) 8. Seal and Gasket Kits

2. The TCM 80-way Electrical Connector 9. C3/C4 Reaction Plates
3. The Transmission 20-way Electrical Connector 10. C3/C4 Clutch Housings
4. J1939 Lever and Pushbutton Shift Selectors 11. C3/C4 Return Plate and Spring Assembly
5. Hydraulic Valve Body Components 12. Retarder Valve Body Components
6. All Solenoids 13. Retarder Accumulators
7. Internal Wiring Harnesses 14. J1939 Communications

Allison Transmission
General Motors Corporation
Indianapolis, IN 46206-0894

JDM / SL4154EN
Copyright 2005 General Motors Corporation. All Rights Reserved.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 2 of 38

Each of these product changes will be discussed in greater detail below. There are several compatibility issues between
WTEC III and Allison 4th Generation Controls transmissions. Please read this information completely to avoid
potential mismatches between former and current 3000 and 4000 Product Families transmission components.
Figure 1 illustrates the external components that make up the Allison 4th Generation Controls system. The vehicle OEM
is responsible for the specific external wiring harness and electrical connectors. A complete system overview and
extensive troubleshooting information can be found in the Allison 4th Generation Controls Troubleshooting Manual
(TS3989EN).

TRANSMISSION
CONTROL
MODULE
(TCM)

ALLISON DOC™
FOR PC

VEHICLE
INTERFACE
MODULE
DIAGNOSTIC J1939 (VIM)
TOOL CONNECTOR
CONNECTOR VIW
CONNECTOR
(OPTIONAL)
ALLISON DOC™
FOR PDA DEUTSCH 9-PIN
DIAGNOSTIC TOOL
CONNECTOR VIM
CONNECTOR
SCI (J1587)
CONNECTOR
(OPTIONAL) RETARDER ACCUMULATOR
COMPACT CONNECTOR
PUSHBUTTON RETARDER
SELECTOR MODULATION TRANSFER CASE CONNECTOR
REQUEST (RMR) (3000 PRODUCT FAMILY 7– SPEED)
CONNECTOR

SENSOR HARNESS
CONNECTOR (OPTIONAL) OUTPUT
SPEED SENSOR
REMOTE LEVER CONNECTOR
SELECTOR SHIFT
SELECTOR
CONNECTOR
RETARDER TEMP. SENSOR CONNECTOR
(3000 PRODUCT FAMILY)

THROTTLE POSITION
SENSOR (TPS) TURBINE
REMOTE CONNECTOR SPEED SENSOR ENGINE
PUSHBUTTON CONNECTOR SPEED
SELECTOR (4000 PRODUCT SENSOR
THROTTLE FAMILY) CONNECTOR
POSITION
E
D
O
M

SENSOR (TPS)
R
N
D

Bulkhead Connector (Optional)

RETARDER “PCS5”
STRIP PUSHBUTTON SOLENOID
SHIFT SELECTORS CONNECTOR
(EUROPEAN
OEM)

1
20-WAY
2
TRANSMISSION
R 3
FEEDTHROUGH
N HARNESS
D D
NOTE: Illustration is not to scale. Actual harness CONNECTOR
N

R
configuration may differ from this illustration.
V09274.00.00

Figure 1.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 3 of 38

ALLISON 4TH GENERATION CONTROLS TCM

Allison 4th Generation Controls TCMs are available in four models. Their physical characteristics are shown in Figure 2.

MODEL NUMBER
MANUFACTURER'S
PART NUMBER

MODEL/MODELE: XXX MOTOROLA P/N XXXXXXX

TCM S/N: XXXXXXXXXXXXXXXX

BASE P/N DATE CODE/DATE DE FABRICATION: XXXX–XX–XX

SERIAL XXXXXXXX

NUMBER

DATE CODE
BASE PART
NUMBER

TOP VIEW BOTTOM VIEW

TCM
P/N 29544775 V09005.02.00

Figure 2.

• Model A40 (P/N 29544772) is for 1000 Series GM pickup truck transmissions and is not offered to 3000 or 4000
Product Family transmissions.
• Model A41 (P/N 29544773) is the basic configuration used by 1000/2000/2400 Series and 6-speed 3000/4000
Product Family transmissions in a 12V electrical system.
• Model A42 (P/N 29544774) is the expanded configuration used by 3000/4000 Product Family retarder equipped or
7-speed transmissions in a 12V electrical system.
• Model A43 (P/N 29544775) is the universal configuration and can be used in 12V or 24V applications.
TCM model capabilities are summarized in the following table.
Table 1.
Model
Feature A40 A41 A42 A43
Voltage 12V 12V 12V 12/24V
Zero Crossing Output Speed Signal X
Neutral Start X X X
3000/4000 Product Family Retarder X X
3000/4000 Product Family 7-speed X X
J1939 CAN X X X X
J2284 High Speed CAN X X X X
J1850 Class 2 X
Limited J1708/J1587 X X
ISO 9141 Communications X
The model-type in the TCM calibration must match the TCM model-type. If the two model-types do not match, the TCM
will not load the calibration. The PCCS load station will report an “Invalid Cal” status. The condition can be corrected by
loading a different calibration with the same model-type as the TCM.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 4 of 38

TCM 80-WAY CONNECTOR

The TCM connects to the OEM wiring harness at a single 80-way connector manufactured by AFL Automotive (EPC).
The connector is available in a straight backshell or 90 degree wire dress configuration, as specified by the vehicle OEM.
Refer to Appendix E of the Allison 4th Generation Controls Troubleshooting Manual (TS3989EN) for detailed
illustrations and service instructions.
A bolt retains the connector to the TCM. The torque specification for the bolt is 2.0–5.5 N·m (18–48 lb inch). AFL also
manufactures a cam lever-lock assembly, which is presently only used in some GM trucks.
TRANSMISSION 20-WAY CONNECTOR
AFL Automotive manufactures the 20-way transmission connector. The design is similar to the 80-way connector. A bolt
retains the connector to the transmission internal wiring harness standoff assembly. The torque specification for the bolt
is 2.0–3.2 N·m (18–28 lb inch).
Refer to Appendix E of the Allison 4th Generation Controls Troubleshooting manual (TS3989EN) for detailed
illustrations and service procedures for the 20-way AFL connector.
J1939 LEVER AND PUSHBUTTON SHIFT SELECTORS

HOLD OVERRIDE HOLD OVERRIDE

BUTTON BUTTON
MODE INDICATOR
(LED) MODE INDICATOR
R
(LED)
1
2
MODE BUTTON N
3 D MODE BUTTON
4 6 7 6
6
5
1
MODE ID 5
MODE ID
D 1 4 1
DIGITAL DISPLAY* DIGITAL DISPLAY*
N 3
R 2
1

DISPLAY MODE DISPLAY MODE

DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON
SIX-SPEED, SEVEN-SPEED, CONTOURED
LEFT-HAND RIGHT-HAND BEZEL
LEVER SELECTOR LEVER SELECTOR
WITH REVERSE WITH REVERSE
IN REAR TO FRONT

DIGITAL DISPLAY*
7 1 MODE ID
MODE 6
MODE
INDICATOR (LED) 1
Push simultaneously
to enter diagnostic
mode and fluid
level check

PUSHBUTTON SELECTORS

* NOTE: The first number displayed is highest forward range available and second number is range
attained in selected position.
Visually check to confirm range selected. If display is flashing, shift is inhibited. V07343.04.00

Figure 3.

Allison 4th Generation Controls shift selectors communicate with the TCM via the 1939 Controller Area Network (CAN).
Allison 4th Generation Controls shift selectors no longer use serial and parallel data lines as the primary means of
communication with the transmission controller. Allison J1939 based shift selectors exchange digital messages with the
Allison 4th Generation TCM via the vehicle’s CAN backbone. Additionally, the shift selectors can provide directional
commands to the TCM on an analog ‘back up’ wire. The shift selector generates a pulse width modulated signal to
communicate range requests (Neutral, Drive, or Reverse) to the TCM in the event that J1939 communications are lost.
Allison 4th Generation controls shift selectors support the same functionality as WTEC III selectors, including selected
range, oil level and diagnostic displays; however, they are equipped with an additional display digit to indicate ‘range
monitored’, similar to WTEC II shift selectors. The 4th Generation shift selectors rely on vacuum fluorescent technology
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 5 of 38

to produce display characters that are blue-green in color and 13.4 mm in height, as opposed to 12 mm in WTEC III shift
selectors. Finally, Allison 4th generation lever shift selectors use a finger grip button instead of the thumb button as the
detent release.
The OEM wiring harness connects to Allison 4th Generation shift selector at 16-way Delphi-Packard Micro-Pack 100W
series connectors. OEMs are able to select these connectors in either a straight or 90 degree configuration. Detailed
service instructions appear in Appendix E of the Allison 4th Generation Controls troubleshooting manual.

HYDRAULIC VALVE BODY COMPONENTS

The Allison 4th Generation Controls system hydraulic control module contains many new features that make the new
control module incompatible with the former WTEC II or WTEC III electronic control unit (ECU) and controls system.
An Allison 4th Generation Controls hydraulic control module will not work with former control system. Variable bleed
solenoids have replaced the former pulse width modulation (PWM) clutch control solenoids. A one-piece aluminum
solenoid valve body is used in place of the former cast iron rotating and stationary valve bodies. The main valve body has
been redesigned to accommodate changes to the C1 and C2 latch valves, main regulator and control main regulator valves.
Other valves, springs, and stops have also been changed. Figures 4a and 4b show the Allison 4th Generation control
module components.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 6 of 38

10
1 9

11
8
12
47
43 48 50
46 14
49
39 44 45
42 13
7 40 41
26
2 38
22
6
25
4 37
24
5 23 15

36
21
35 20
28
29 19
3 32 30 18
27 16
34 33 31 17

58 61
51
66
52 67
59 68
53
69
57 70
60
54
71
62 56
72
55 73
74
75
94 96 65
95 76
77
78
63 64
79
80
89 91
90 93
92

84 86
85 88 82
87 83
81

V07031.04.00

Figure 4a.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 7 of 38

1 (Cont’d)

100 140
139
105
101
106 104 141
102
103
131 109
110
135 127
108
99 123 107
97 113
117 112
98
111
116
136 115
137 114
138 132 118
133 119
134 120
128
129 121
130 124 122
125 180
126

152 142

160
153 143
159
154
158 155
144
157 145
156 146
161
162

163
164 165
166
177 170 167

149 150 147

176 148
175 151
174 168 169
173 172
171

179
178
V09481.00.00

Figure 4b.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 8 of 38

Table 2. 16 Group Parts List

REF
NO. NOMENCLATURE PART NO. REQ
1 Valve Assembly, Control, 3000 Product Family, 4 inch, With OLS 29542902 1
1 Valve Assembly, Control, 3000 Product Family, 2 inch, With OLS 29542903 1
1 Valve Assembly, Control, 3000 Product Family, 7 inch, Without OLS 29542904 1
1 Valve Assembly, Control, 4000 Product Family, 4 inch, With OLS 29542907 1
1 Valve Assembly, Control, 4000 Product Family, 2 inch, With OLS 29542908 1
1 Valve Assembly, Control, 4000 Product Family, 4 inch, Straight-7, Without OLS 29542909 1
1 Valve Assembly, Control, 4000 Product Family, 4 inch, Straight-7, With OLS 29542910 1
1 Valve Assembly, Control, 4000 Product Family, 4 inch, Straight-7, Annodized 29542500** 1
2 Filter Assembly Kit, Suction 29544785 1
3 Gasket, Suction Filter 29537066 1
4 Filter and Seal Assembly, Suction 29543067 1
5 Filter Assembly, Suction 29542990* 1
6 Seal, Face 29542991 1
7 Bolt, Flange Hd, M6 x 1.0 x 30 mm 11515316 3
8 Harness Assembly, Internal, 3000 Product Family, 6-Speed, With OLS 29544671 1
8 Harness Assembly, Internal, 3000 Product Family, 7-Speed, Without OLS 29544673 1
8 Harness Assembly, Internal, 4000 Product Family, 6-Speed, With OLS 29544674 1
8 Harness Assembly, Internal, 4000 Product Family, 7-Speed, Without OLS 29544675 1
8 Harness Assembly, Internal, 4000 Product Family, 7-Speed, With OLS 29544676 1
9 Connector Assembly 29543062* 1
10 Connector 29543073* 1
11 Seal, Harness Standoff 29542084 1
12 Sealring 12092195 1
13 Standoff, Wiring Harness, 3000 Product Family 29544677* 1
13 Standoff, Wiring Harness, 4000 Product Family 29544678* 1
14 Grommet 29544669* 1
15 Bolt, 20F Connector 29543082* 1
16 Sensor, Temperature (OILT) 12129691 1
17 Connector Assembly, Two-Way Plug (TEMP) 29528593** 1
18 Connector, 2-Way 12047662 1
19 Terminal, Socket 12047767 1
20 Terminal, Socket 12047767 1
21 Lock, Secondary 12047664 1
22 Connector Assembly, Two-Way Plug (SS1) 29528597** 1
23 Terminal, Socket 12124639 1
24 Terminal, Socket 12124639 1
25 Connector, 2 Way 29541590 1

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 9 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
26 Plate, Harness Channel 29543019 1
27 Connector Assembly, Three-Way Plug (OLS) 29528611** 1
28 Connector, Plug, 3-Way 12064758 1
29 Terminal, Socket 12047767 3
30 Lock, Secondary, TPA 12047783 1
31 Connector Assembly, Two-Way Plug (SS2) 29528597** 1
32 Connector, 2-Way 29541590 1
33 Terminal, Socket 12124639 1
34 Terminal, Socket 12124639 1
35 Connector Assembly, Two-Way Plug (PCS3)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
36 Connector Assembly, Two-Way Plug (PCS4)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
37 Connector Assembly, Two-Way Plug (PCS6)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
38 Connector Assembly, Two-Way Plug (MAIN MOD)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
39 Connector Assembly, Two-Way Plug Turbine Speed Sensor (NT1). 3000 29528601** 1
Product Family Only
40 Terminal, Socket 12110236 1
41 Terminal, Socket 12110236 1
42 Connector 15490953 1
43 Connector Assembly, Two-Way Plug (PS1) 29528599** 1
44 Terminal, Pin 12066337 1
45 Terminal, Pin 12066337 1
46 Connector, 2-Way 12110139 1
47 Connector Assembly, 2 Way (TCC)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
48 Connector Assembly, 2 Way (PCS1)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
49 Connector Assembly, 2 Way (PCS2)
Service 29542997 Connector Assembly With 29544184 Connector 29544184 1
Assembly Kit
50 Bolt, Shoulder, M6 x 1.0 x 45 mm 29536564 3

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 10 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
51 Bracket, Solenoid, Right-Side 29542946 1
52 Bolt, Flange Hd, M6 x 1.0 x 45 mm 11516059 2
53 Seal, Face 23046376 3
54 Spring, Accumulator 8678805 2
55 Plug Accumulator 29536230 2
56 Plug Accumulator 29536230 2
57 Spring, Accumulator 8678805 2
58 Bracket and Pressure Switch Assembly 29542944 1
59 Switch, Pressure, PS1 29542838* 1
60 Bracket, Solenoid, Left-Side 29542945 1
61 Bolt, Flange Hd, M6 x 1.0 x 95 mm 11515310 12
62 Body Assembly, Solenoid 29542934** 1
63 Body Assembly, Solenoid Valve and Pin 29542935 1
64 Body, Solenoid Valve 29542822 1
65 Pin, Dowel 29542954 3
66 Solenoid, TCC, Variable Bleed, N/C. Connector Body Color Coded 29544297 1
Natural Brown
67 O-ring, 13.0 mm ID 29535518 1
68 O-ring, 10.5 mm ID 29542976 1
69 Valve, TCC 29542937 1
70 Spring, TCC 29542938 1
71 Solenoid, PCS 1, Variable Bleed, N/O. Connector Body Color Coded Black 29541897 1
72 O-ring, 13.0 mm ID 29542975 1
73 O-ring, 10.5 mm ID 29542976 1
74 Valve, Clutch Trim 29542939 1
75 Spring, Trim 29542936 1
76 Solenoid, PCS 2, Variable Bleed, N/O. Connector Body Color Coded Black 29541897 1
77 O-ring, 13.0 mm ID 29542975 1
78 O-ring, 10.5 mm ID 29542976 1
79 Valve, Clutch Trim 29542939 1
80 Spring, Trim 29542936 1
81 Clip 29531022 1
82 Valve, Diagnostic 29542940 1
83 Spring, Diagnostic 29542941 1
84 Solenoid, PCS 3, Variable Bleed, N/C. Connector Body Color Coded 29544297 1
Natural Brown
85 O-ring, 13.0 mm ID 29542975 1
86 O-ring, 10.5 mm ID 29542976 1
87 Valve, Clutch Trim 29542939 1
* Serviced Only As An Assembly—Not Available As A Detail Part.
** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 11 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
88 Spring, Trim 29542936 1
89 Solenoid, PCS 4, Variable Bleed, N/C. Connector Body Color Coded 29544297 1
Natural Brown
90 O-ring, 13.0 mm ID 29542975 1
91 O-ring, 10.5 mm ID 29542976 1
92 Valve, Clutch Trim 29542939 1
93 Spring, Trim 29542936 1
94 Solenoid, Main Mod, Variable Bleed, N/C. Connector Body Color Coded 29544297 1
Natural Brown
95 O-ring, 13.0 mm ID 29542975 1
96 O-ring, 10.5 mm ID 29542976 1
97 Bolt, Flange Hd, M6 x 1.0 x 20 mm. 3000 Product Family Only 11515315 2
98 Sensor, Speed. 3000 Product Family Only 29503531 1
99 Bolt, Flange Hd, M6 x 1.0 x 60 mm 11515309 2
100 Plate, Solenoid Separator, 3000 Product Family 29542932 1
100 Plate, Solenoid Separator, 4000 Product Family 29542933
101 Body Assembly, Main Valve, 6-Speed 29542921** 1
101 Body Assembly, Main Valve, 7-Speed 29542922**
102 Pin, Retention, 5 OD x 43 mm 23049345 1
103 Valve, Converter Flow 23049315 1
104 Spring, Converter Flow, 14.1 OD x 42.1 mm 23049326 1
105 Stop, Converter Flow 23049337 1
106 Pin, Retention, 3 OD x 43 mm 29500822 1
107 Valve, Lube Regulator 23049316 1
108 Spring, Lube Regulator, 11.10 OD x 46.3 mm 23049327 1
109 Stop, Lube Regulator 23049338 1
110 Pin, Retention, 5 OD x 43 mm 23049345 1
111 Valve, Main Regulator 29542927 1
112 Spring, Main Regulator, 22 OD x 98.5 mm 29500963 1
113 Stop, Main Regulator 29503663 1
114 Valve, Control Main 29542925 1
115 Spring, Control Main, 16.0 OD x 51.41 mm 29542926 1
116 Clip, Control Main 29531022 1
117 Pin, Retention, 2.5 OD x 40 mm 29500823 1
118 Solenoid Assembly 29537369 1
119 O-ring, 18.8 mm ID 29503384 1
120 O-ring, 14.0 mm ID 29503382 1
121 Body, Control Valve, 6-Speed 29542923 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 12 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
121 Body, Control Valve, 7-Speed 29542924 1
122 Pin, Spring, 5 OD x 55 mm 11513011 1
123 Pin, Retention, 5 OD x 43 mm 23049345 1
124 Valve, C2 Latch 29544937 1
125 Spring, C2 Latch, 16.29 OD x 35.02 mm 29542929 1
126 Stop, C2 Latch 29542930 1
127 Pin, Retention, 5 OD x 43 mm 23049345 1
128 Valve, Exhaust Backfill 23049320 1
129 Spring, Exhaust Backfill, 7.8 OD x 29.2 mm 23049391 1
130 Stop, Exhaust Backfill 23049342 1
131 Pin, Retention, 5 OD x 43 mm 23049345 1
132 Valve, C1 Latch 29542928 1
133 Spring, C1 Latch, 16.29 OD x 35.02 mm 29542929 1
134 Stop, C1 Latch 29542930 1
135 Pin, Retention, 3 OD x 43 mm 29500822 1
136 Valve, Converter Regulator 29507462 1
137 Spring, Converter Regulator, 11 OD x 30.3 mm 29507456 1
138 Stop, Converter Regulator 29538477 1
139 Bolt, Shoulder, M6 x 1.0 x 45 mm 29536564 2
140 Sensor Assembly, Oil Level 29530105 1
141 Ferrule, Viton® 29536567 4
142 Plate, Separator, 3000 Product Family, 6-Speed 29542915 1
142 Plate, Separator, 3000 Product Family, 7-Speed 29542916 1
142 Plate, Separator, 4000 Product Family, 6-Speed 29542917 1
142 Plate, Separator, 4000 Product Family, 7-Speed 29542918 1
143 Gasket, Channel Plate, 3000 Product Family 29542919 1
143 Gasket, Channel Plate, 4000 Product Family 29542920 1
144 Plate Assembly, Channel, 3000 Product Family, 2 inch 29524437** 1
144 Plate Assembly, Channel, 3000 Product Family, 4 inch 29524438** 1
144 Plate Assembly, Channel, 3000 Product Family, 7 inch 29542911** 1
144 Plate Assembly, Channel, 4000 Product Family, 2 inch 29524436** 1
144 Plate Assembly, Channel, 4000 Product Family, 4 inch 29524439** 1
144 Plate Assembly, Channel, 4000 Product Family, 4 inch, Straight 7 29542912** 1
144 Plate Assembly, Channel, 4000 Product Family, 4 inch, Straight 7, Annodized 29542499** 1
145 Pin, Dowel, 10 x 50 mm 23046354 2
146 Plate, Oil Transfer, 3000 Product Family, 2 inch 29535699 1
146 Plate, Oil Transfer, 3000 Product Family, 4 inch 29524442 1
146 Plate, Oil Transfer, 3000 Product Family, 7 inch 29542913 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 13 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
146 Plate, Oil Transfer, 4000 Product Family, 2 inch 29533076 1
146 Plate, Oil Transfer, 4000 Product Family, 4 inch 29533077 1
146 Plate, Oil Transfer, 4000 Product Family, 4 inch, Straight 7 29542914 1
146 Plate, Oil Transfer, 4000 Product Family, 4 inch, Straight 7, Annodized 29542574 1
147 Plug Assembly, Oil Drain 29534362 1
148 O-ring, 16.4 mm ID 23019664 1
149 Plug Assembly, Pressure Tap, 3000 Product Family 29500034 10
149 Plug Assembly, Pressure Tap, 4000 Product Family 29500034 9
150 O-ring, 8.9 mm ID 23043446 1
151 Plug, Pressure Tap, 7/16-20 29541018* 1
152 Filter, Oil, 2 inch 29538231 2
152 Filter, Oil, 4 inch 29538232 2
153 O-ring, 75.9 mm ID 29507437 2
154 O-ring, 85.3 mm ID 29543926 2
155 Gasket, Filter Cover 29524449 2
156 Cover, Filter 29524447 2
156 Cover, Filter, Annodized 29542575 2
157 Plug, Accumulator 29536230 1
158 Spring, Accumulator 8678805 1
159 Bracket, Accumulator 29542953 1
160 Bolt, Flange Hd, M6 x 1.0 x 60 mm 11515309 4
161 Body Assembly, C6 Clutch 29542947** 1
162 Body, C6 Clutch 29542948 1
163 Spring, 10.75 OD x 16.71 mm 29542949 1
164 Valve, C6 Enable 29542950 1
165 Solenoid Assembly, C6 Enable 29537369 1
166 O-ring, 14.0 mm ID 29503382 1
167 O-ring, 18.8 mm ID 29503384 1
168 Plate, Protective, Solenoid 29505628 1
169 Nut, Speed, Push-on 29505629 1
170 Pin, Retaining, 2.5 OD x 30 mm 29511647 1
171 Spring, Trim 29542936 1
172 Valve, Trim 29542951 1
173 Solenoid, PCS 6, Variable Bleed, N/C. Connector Body Color Coded 29544297 1
Natural Brown
174 O-ring, 10.5 mm ID 29542976 1
175 O-ring, 13.0 mm ID 29542975 1
176 Bracket, Solenoid Retaining 29542952 1

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 14 of 38

Table 2. 16 Group Parts List (cont’d)

REF
NO. NOMENCLATURE PART NO. REQ
177 Screw, Hex Socket Hd 29535575 1
178 Bolt, Flange Hd, M10 x 1.5 x 100 mm, 3000 Product Family, 4 inch 29541274 25
178 Bolt, Flange Hd, M10 x 1.5 x 100 mm, 4000 Product Family, 4 inch 29541274 34
179 Bolt, Flange Hd, M10 x 1.5 x 55 mm, 3000 Product Family, 2 inch 29541286 32
179 Bolt, Flange Hd, M10 x 1.5 x 55 mm, 3000 Product Family, 4 inch 29541286 7
179 Bolt, Flange Hd, M10 x 1.5 x 55 mm, 4000 Product Family, 2 inch 29541286 43
179 Bolt, Flange Hd, M10 x 1.5 x 55 mm, 4000 Product Family, 4 inch 29541286 9
180 Gasket, Case, 3000 Product Family 29503283 1
180 Gasket, Case, 4000 Product Family 29501099 1

The former and current valve bodies, solenoids, pressure switches, separator plates, valves, springs and stops are not
interchangeable. All former valves body components have been maintained for service. Use former valve body parts to
service transmissions with WTEC II and III controls systems. Use current valve body parts to service transmissions with
Allison 4th Generation Controls systems.
Variable Bleed Solenoids
The Allison 4th Generation Controls system uses variable bleed solenoids to apply and release the transmission’s clutches.
Variable bleed solenoids permit improved clutch control. The output (pressure) of these solenoids is proportional to the
current supplied by the TCM. As a result, the solenoids are known as pressure control solenoids and designated with the
abbreviation PCS. The Allison 4th Generation Controls System for 3000 and 4000 Product Families uses up to eight
variable bleed solenoids. PCS1 through PCS4 control the C1 through C5 clutches. PCS5 applies the retarder, if so
equipped, or the differential-lock clutch in 3700 SP models. PCS6 controls the C6 clutch in 7-speed transmissions. The
remaining two variable bleed solenoids are the TCC solenoid, which controls the torque converter lockup clutch, and the
main modulation (main mod) solenoid. The main mod solenoid is discussed in greater detail in the next section.
PCS1 and PCS2 are normally-open solenoids. A normally-open solenoid produces maximum output pressure when its
coil is electrically de-energized and zero output pressure when full current is supplied to its coil. The remaining variable
bleed solenoids (PCS3 through PCS6, main mod, and TCC) are normally-closed solenoids. A normally-closed solenoid
produces no output pressure when its coil is electrically de-energized and maximum output when fully energized.
Normally-open solenoids PCS1 and PCS2 provide a ‘limp-home’ capability by continuing to supply clutch pressure in
the event of a loss of electrical power to the TCM.
The 3000/4000 Product Family Allison 4th Generation Controls normally-closed variable bleed solenoids have the exact
same physical dimensions as the 1000/2000 Allison 4th Generation Controls TCC solenoid; however, these solenoids
are not interchangeable. To prevent mis-assembly between product families, the 1000/2000 Allison 4th Generation
Controls TCC solenoid and the 3000/4000 Product Family normally-closed variable bleed solenoids have color-coded
electrical connectors to identify the difference between the two. The 1000/2000 Product Family Allison 4th Generation
Controls TCC solenoid P/N 29541898 has a RED end cap and the 3000/4000 Product Family Allison 4th Generation
Controls normally-closed variable bleed solenoids P/N 29544297 have natural BROWN end cap.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 15 of 38

RED BROWN
COLORED COLORED
SOLENOID SOLENOID
END CAP END CAP

1000 AND 2000 PRODUCT FAMILY 3000 AND 4000 PRODUCT FAMILY
VBS TCC SOLENOID VBS SOLENOID
P/N 29541898 P/N 29544297

V09560.00.00

Figure 5.

The current variable bleed solenoids are not compatible with the former WTEC III Controls System, which uses PWM
solenoids. Likewise, the former PWM clutch solenoids are not compatible with the current Allison 4th Generation
Controls System. The former PWM solenoids have been maintained for service of WTEC III transmissions.
Main Modulation Solenoid
The Allison 4th Generation controls system includes a main modulation solenoid in 3000 and 4000 Product Families
transmissions. Modulated main pressure results in improved cooler flow and reduced pump losses when throttle position
and output speed is low. The Allison 4th Generation Controls TCM commands the main mod solenoid ON when all of
the following conditions are simultaneously met:
1. Sump temperature is greater than 30ºC (86ºF) and less than 150ºC (302ºF) [greater than –5ºC (23ºF) and less
than 225ºC (437ºF) for 4700 and 4800 model transmissions].
2. Engine speed less than 1200 rpm in all ranges except Neutral. There are no restrictions on engine speed in
Neutral.
3. Throttle percentage less than 15 percent in Reverse, Low (7-speeds), First or Second range. Main mod may be
commanded ON in Neutral at any throttle position.
4. Output speed is less than 250 rpm in Neutral, Reverse, Low (7-speed), First or Second range.
5. The PTO input to the TCM indicates the PTO is OFF.
6. Shift not in progress.
The TCM may activate the main mod solenoid for improved clutch control and transmission response during other
unusual operating situations.
Aluminum Solenoid Valve Body
Allison 4th Generation Controls uses a one-piece cast aluminum solenoid valve body in place of the former cast iron
rotating and stationary valve bodies. The aluminum solenoid valve body houses the PCS1 through PCS4, Main Mod and
TCC solenoids. A left and right side steel bracket holds each of these solenoids in place. A solenoid trim valve is located
beneath each PCS solenoid. Similarly, the TCC trim valve is situated under the TCC solenoid. The TCC valve spring is
inserted inside a hollow section of the lower portion of the TCC valve.

NOTE: Be sure the TCC valve spring is retained inside the TCC valve pocket by firmly twisting
the spring during insertion.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 16 of 38

The Allison 4th Generation Controls system incorporates accumulator plugs and springs at the output port of each range
clutch solenoid. There are four plugs and springs in the solenoid valve body and one plug and spring in the C6 valve body
on seven speed units. These accumulators improve shift quality by reducing pressure spikes in the clutch hydraulic
circuits during clutch application. The accumulators and springs are held in place by the solenoid retainer brackets.
The former stationary and rotating valve body components and PWM solenoids have been maintained for service.
Assembly Procedure for 3000 and 4000 Product Families Aluminum Valve Body
Observe the following torque procedure when reassembling valve body assemblies to the channel plate. Tighten all
M6 valve body bolts to one-half of the nominal torque, and then re-tighten all bolts to the specified torque valve of
10–13 N·m (7–10 lb ft). Torque the bolts in the sequence described below:
1. Start from the center of the bolt pattern and work outward in a circular sequence.
2. Tighten bolts to 50 percent of nominal torque, i.e. 5–6 N·m (3–5 lb ft).
3. Continuing to work from center outward, re-tighten bolts to 10–13 N·m (7–10 lb ft).
Diagnostic Valve
The solenoid valve body also houses the diagnostic valve. The diagnostic valve is a two position valve that permits the
diagnostic pressure switch (PS1) to perform two functions. When the C5 clutch is filled as in reverse, neutral, or first
range, the diagnostic valve aligns the pressure switch to the PCS2 solenoid regulator valve. This allows the TCM to verify
proper C3 clutch control while shifting into and out of reverse range. Alternatively, while C5 is exhausted as in second
through sixth ranges, the diagnostic valve aligns the pressure switch to the C1 and C2 latch valves, permitting the TCM
to verify proper latch valve response in second through sixth ranges. A spring clip retains the diagnostic valve in its bore.
The small end of spring compressor tool J 47942 is designed to compress the diagnostic valve spring during assembly.

SOLENOID VALVE BODY

J 47942

DIAGNOSTIC VALVE CLIP

V09574.00.00

Figure 6.

Diagnostic Pressure Switch

The diagnostic pressure switch (PS1) is mounted to the left-side solenoid bracket on the solenoid valve body assembly
and performs two functions.
• When the C5 clutch is filled, PS1 senses PCS2 solenoid regulator valve position to verify proper C3 clutch control
in reverse, neutral and first range.
• When the C5 clutch is exhausted as in second through sixth range, PS1 verifies the position of the C1 and C2 latch
valves.
PS1 is a normally-closed switch. Note: this is opposite of the WTEC II/III C3 pressure switch. When there is no
pressure at the switch, PS1 is closed completing an electrical circuit between the PS1 signal wire and the TCM analog
ground wire. When pressure is supplied to the switch, PS1 opens and the ground is removed from the PS1 signal wire.
See Allison 4th Generation Controls system schematic in Appendix J of TS3989EN for pin designations and wire
numbers.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 17 of 38

PS1 is serviced with the complete pressure switch and solenoid bracket assembly. In the event that the transmission is
exposed to ethylene glycol contamination, the PS1 pressure switch and bracket assembly must be replaced.
Redesigned Main Valve Body
The Allison 4th Generation Controls main valve body has been redesigned to accommodate the current main regulator
valve, control main regulator valve, C1 and C2 latch valves. These valves will not fit in the former main valve body and
the former valves will not fit in the current main valve body.

NOTE: To be sure the correct valve body is used, align roll pin (P/N 11513011) with the hole in
the Allison 4th Generation separator plate.

If the roll pin does not line up with the hole in the large steel separator plate, check to see if the correct separator plate or
valve body is installed.
A spring clip retains the current control main regulator valve in the current main valve body. Use the large end of spring
compressor tool J47942 to compress the control main regulator valve spring during assembly.
The following former main valve body assembly components have been maintained for service:
• 6-speed and 7-speed main valve bodies
• Main regulator valve
• Control main regulator valve, spring and stop
• C1 and C2 latch valves, springs and stops
All other valves are common with former 3000 and 4000 Product Families ’95 Controls valve body.
90 Degree Solenoid Connectors
Allison 4th Generation Controls system uses 90 degree connectors to connect the variable bleed solenoids to the current
internal wiring harness. Disengage solenoid connectors from solenoids by pressing straight back on the solenoid
connector latch finger using terminal removal tool J 38125-13 or a small flat tip screwdriver. Exercise caution to avoid
exerting a lateral force on the latch finger. Side loading the finger may result in damage to the solenoid connector.
Current 90 degree solenoid connector bodies and terminals are not serviceable individually. Service kit 29544184
contains a pre-assembled 90 degree connector assembly crimped onto approximately 20 inches (0.5 m) of wire plus two
‘in-line’ splice connectors. See Allison 4th Generation Controls Troubleshooting Manual (TS3989EN), Appendix E for
the recommended 90 degree solenoid connector repair procedures.
Internal Wiring Harness
The Allison 4th Generation Controls System contains redesigned internal wiring harnesses, which incorporate the current
standoff tower and 20-way connector. The current wiring harness incorporates a TRANSID feature, which allows the
TCM to adjust calibration parameters based on the type of transmission hardware it detects. The initial versions of the
current internal harnesses are wired for TransID “A”.
The former and current internal wiring harnesses are not interchangeable. The former WTEC TransID 1, 2, and 3 wiring
harnesses have been maintained for service.
Channel Plate for 7-Speed Transmission Models
The Allison 4th Generation Controls system includes revised channel plates for seven-speed transmission models. Six-
speed transmissions will continue to use the same channel plates as the WTEC controls system.
The following applies to 3000 Product Family seven-speed models. The former 3000 Product Family seven-speed
channel plate has been completely cancelled. Use the current 3000 Product Family seven-speed channel plate to service
MD 3070PT and 3700 model transmissions with WTEC II and III controls as well as 3700 model transmissions with
Allison 4th Generation controls.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 18 of 38

The following applies to 4000 Product Family seven-speed models. The former 4000 Product Family seven-speed
channel plate has been maintained for service. Use the former 4000 Product Family seven-speed channel plate to service
HD 4070, HD 4076, 4700 model, and 4800 model transmissions with WTEC II and WTEC III controls. Use the current
4000 Product Family seven-speed channel plate to service 4700 and 4800 model transmissions with Allison 4th
Generation controls.
Refer to the following table for list of serviceable oil transfer (channel) plate part numbers.

WTEC II and III Controls Allison 4th Generation Controls

Part Part
Part Name Number Part Name Number
3000 Product Family, 2 inch 29535699 3000 Product Family, 2 inch 29535699
3000 Product Family, 4 inch 29524442 3000 Product Family, 4 inch 29524442
3000 Product Family, 7 inch 29542913 3000 Product Family, 7 inch 29542913
4000 Product Family, 2 inch 29533076 4000 Product Family, 2 inch 29533076
4000 Product Family, 4 inch 29533077 4000 Product Family, 4 inch 29533077
4000 Product Family, 4 inch, Straight 7 29530533 4000 Product Family, 4 inch, Straight 7 29542914
4000 Product Family, 4 inch, Straight 7, 29542574
Annodized

SEAL AND GASKET KITS

Allison Transmission has introduced a series of seal and gasket kits for use with Allison 4th Generations controls. The
former seal and gaskets kit have been maintained for service. The following table provides a list of former and current
seal and gaskets kit.
Use former seal and gasket kits to service transmissions with WTEC II and III controls systems. Use current seal and
gasket kits to service transmissions with Allison 4th Generation controls. Refer to the following table to determine
available seal and gasket kits.

WTEC II and III Controls Allison 4th Generation Controls

Kit Name Number Kit Name Number
MD Straight-Thru S&G Kit 29543319 MD Straight-Thru S&G Kit 29544791
98 Redesign Retarder S&G Kit 29544794 Retarder S&G Kit 29544795
MD Control Module (‘92 Controls) S&G Kit 29544784 MD Control Module S&G Kit 29544792
Transfer Case S&G Kit 29537869 Transfer Case S&G Kit 29544827
MD Control Module (‘91 Controls) S&G Kit 29544783
MD Retarder (pre-98) 29543315

HD Straight-thru Overhaul Kit 29544786 HD Straight-Thru Overhaul Kit 29544796

HD Retarder Overhaul Kit 29544787 HD Retarder Overhaul Kit 29544797
HD Control Module S&G Kit 29544788 HD Control Module S&G Kit 29544798
HD 4070 S&G Kit 29542212 HD 4070 S&G Kit 29544828

C3/C4 CLUTCH ASSEMBLIES

The Allison 4th Generation Controls system features thicker C3 and C4 clutch reaction plates, an integrated piston return
plate assembly, redesigned pistons, and clutch housings. One additional reaction plate has been added to the C3 and C4
clutch pack, increasing the total number of reaction plates to five in the C3 clutch pack, and to six in the C4 clutch pack.
The C3 and C4 apply spring assembly has been eliminated, and the current piston acts directly against the first reaction
plate when the clutch is applied.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 19 of 38

2
3

6
1

4 10

5 7
8 14
9 15
16
17

20
11
12
18
19 13

21
22
23
24

WTEC II / III

2 3
4

5 6
7 11
8 12
13

14
15 10

16

17
18

ALLISON 4TH GENERATION CONTROLS

C3 AND C4 CLUTCH ASSEMBLY V09531.00.00

Figure 7.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 20 of 38

Table 3. Former WTEC III 3000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Clutch Assembly 29536667** 1
2 Bolt, M10 x 1.5 x 90 11505328 12
3 Backplate Assembly, C3. Contains 29535006 Backplate Assembly, Three 29503106** 1
29522720 Wear Plates, And Six 11506706 Rivets.
3 Backplate Assembly, C3. Contains 29538532 Backplate Assembly, Three 29538527** 1
29538343 Wear Plates.
4 Backplate Assembly, Clutch. For Use With 29522720 Wear Plates And 29535006 1
11506706 Rivets.
4 Backplate Assembly, Clutch. For Use With 29538343 Wear Plates. 29538532 1
5 Plate, Clutch Wear. Fasten With 11506706 Rivets. 29522720 3
5 Plate, Clutch Wear 29538343 3
6 Rivet, 3 OD x 6 mm 11506706 6
7 Gear, P1 Ring 29542338 1
8 Plate, C3 Clutch Friction 29536336 5
9 Plate, C3 Clutch Reaction 29536345 4
10 Return Spring Assembly 29505570 4
11 Plate, Piston Return 29501424 1
12 Apply Spring Assembly 29537789 1
13 Piston, Clutch, C3 29543065 1
14 Housing Assembly, C3 Clutch, Complete. Contains 29501449 C3 Housing, 29503103** 1
Three 29522720 Wear Plates, And Six 11506706 Rivets.
14 Housing Assembly, C3 Clutch, Complete. Contains 29538345 C3 Housing 29538533** 1
And Three 29538343 Wear Plates.
15 Rivet, 3 OD x 6 mm 11506706 6
16 Plate, Clutch Wear. Fasten With 11506706 Rivets. 29522720 3
16 Plate, Clutch Wear 29538343 3
17 Housing, C3 Clutch. For Use With 29522720 Wear Plates And 11506706 29501449 1
Rivets.
17 Housing, C3 Clutch. For Use With 29538343 Wear Plates. 29538345 1
18 Plate, C4 Clutch Reaction 29536345 5
19 Plate, C4 Clutch Friction 29536336 5
20 Return Spring Assembly 29505570 4
21 Plate, Piston Return 29501424 1
22 Apply Spring Assembly 29537789 1
23 Piston, Clutch, C4 29543065 1
24 Housing Assembly, C4 29501360 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 21 of 38

Table 4. Current Allison 4th Generation Controls 3000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Clutch Assembly 29542751** 1
2 Bolt, M10 x 1.5 x 90 11505328 12
3 Backplate Assembly, C3 29538527** 1
4 Backplate Assembly, Clutch 29538532 1
5 Plate, Clutch Wear 29538343 3
6 Gear, P1 Ring 29542338 1
7 Plate, C3 Clutch Friction 29536336 5
8 Plate, C3 Clutch Reaction 29542748 5
9 Piston Return Plate Assembly 29542754 1
10 Piston, Clutch, C3 29542753 1
11 Housing Assembly, C3 Clutch, Complete 29542755** 1
12 Plate, Clutch Wear 29538343 3
13 Housing Assembly, C3 Clutch 29542756 1
14 Plate, C4 Clutch Reaction 29542748 6
15 Plate, C4 Clutch Friction 29536336 5
16 Piston Return Plate Assembly 29542754 1
17 Piston, Clutch, C4 29542753 1
18 Housing Assembly, C4 29542752 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 22 of 38

Table 5. Former WTEC III 4000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Clutch Assembly 29536668** 1
2 Bolt, Flange Hd, M10 x 1.5 x 100 mm 11515469 14
3 Backplate Assembly, C3. 29542202** 1
4 Backplate Assembly, Clutch 29507815 1
5 Plate, Clutch Wear 29542201 4
6 Rivet, 3 OD x 6 mm 11506706 12
7 Gear, P1 Planetary Ring. Used Only With 29542201 Thrust Plates. Used 29542339 1
Starting With S/N 6610129798.
8 Plate, C3 Clutch Friction 29536340 5
9 Plate, C3 Clutch Reaction 29536349 4
10 Return Spring Assembly 29506206 4
11 Plate, Piston Return 29541014 1
12 Apply Spring Assembly 29542643 1
13 Piston, Clutch, C3 29539518 1
14 Housing Assembly, C3 Clutch, Complete 29542203** 1
15 Rivet, 3 OD x 6 mm 11506706 12
16 Plate, Clutch Wear 29542201 4
17 Housing, C3 Clutch 29505691 1
18 Plate, C4 Clutch Reaction 29536349 5
19 Plate, C4 Clutch Friction 29536340 5
20 Return Spring Assembly 29506206 4
21 Plate, Piston Return 29541014 1
22 Apply Spring Assembly 29542643 1
23 Piston, Clutch, C4 29539518 1
24 Housing Assembly, C4 29505690 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 23 of 38

Table 6. Current Allison 4th Generation Controls 4000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Clutch Assembly 29542501** 1
2 Bolt, Flange Hd, M10 x 1.5 x 100 mm 11515469 14
3 Backplate Assembly, C3. 29542510** 1
4 Backplate Assembly, Clutch 29542511 1
5 Plate, Clutch Wear 29540398 6
6 Gear, P1 Planetary Ring. 29542339 1
7 Plate, C3 Clutch Friction 29536340 5
8 Plate, C3 Clutch Reaction 29542506 5
9 Piston Return Plate Assembly 29542504 1
10 Piston, Clutch, C3 29542503 1
11 Housing Assembly, C3 Clutch, Complete 29542507** 1
12 Plate, Clutch Wear 29540398 6
13 Housing, C3 Clutch 29542508 1
14 Plate, C4 Clutch Reaction 29542506 6
15 Plate, C4 Clutch Friction 29536340 5
16 Piston Return Plate Assembly 29542504 1
17 Piston, Clutch, C4 29542503 1
18 Housing Assembly, C4 29542502 1

** Not Serviced As An Assembly—Order Detail Parts.

 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 24 of 38

The following figures illustrate the differences between the former and current 3000 and 4000 Product Families C3 and
C4 reaction plates and piston return plate assemblies.

NOTCH REMOVED

TOOTH REMOVED

2.41-2.54 mm 3.25-3.35 mm
(00.095-00.100 IN.) (0.128-0.132 IN.)
WTEC II / III ALLISON 4TH
(3000 – P/N 29536345) GENERATION CONTROLS
(4000 – P/N 29536349) (3000 – P/N 29542748)
(4000 – P/N 29542506)
C3 AND C4 REACTION PLATE V09528.00.00

Figure 8.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 25 of 38

WTEC II / III ALLISON 4TH

PLATE GENERATION CONTROLS
(3000 – P/N 29501424) (3000 – P/N 29542753)
(4000 – P/N 29541014) (4000 – P/N 29542504)
RETURN SPRING ASSEMBLY
(3000 – P/N 29505570)
(4000 – P/N 29506206)

C3 AND C4 PISTON RETURN PLATE ASSEMBLY

V09533.00.00

Figure 9.

The current C3 and C4 reaction plates and piston return plate assembly have a different tooth profile than the former
reaction plates and piston return plate. The number and size of the teeth has been changed to prevent mis-assembly of the
current plates into the former C3 and C4 clutch housings.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 26 of 38

TOOTH REMOVED

NOTCH REMOVED

WTEC II / III ALLISON 4TH GENERATION CONTROLS

(3000 — P/N 29538345) (3000 — P/N 29542756)
(4000 — P/N 29505691) (4000 — P/N 29542508)

C3 CLUTCH HOUSING V09530.00.00

Figure 10.

TOOTH REMOVED

NOTCH REMOVED

WTEC II / III ALLISON 4TH GENERATION CONTROLS

(3000 – P/N 29501360) (3000 – P/N 29542752)
(4000 – P/N 29505690) (4000 – P/N 29542502)

C4 CLUTCH HOUSING V09529.00.00

Figure 11.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 27 of 38

Similarly, the current clutch housings have been changed to fit with the current reaction plates and piston return plate
assembly tooth configuration. These housings will not accept the former reaction plates or piston return plate.

WTEC II / III ALLISON 4TH GENERATION CONTROLS

(3000 – P/N 29543065) (3000 – P/N 29542753)
(4000 – P/N 29539518) (4000 – P/N 29542503)

C3 AND C4 PISTON V09527.00.00

Figure 12.

The current C3 and C4 pistons have a taller profile and are designed to react directly against the first clutch reaction plate.
The former pistons reacted against the former piston return plate via the apply spring assembly. The Allison 4th
Generation controls C3 and C4 clutch modules do not use an apply spring assembly.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 28 of 38

WTEC II / III ALLISON 4TH GENERATION CONTROLS

(3000 – P/N 29537789) (NOT USED)
(4000 – P/N 29542643)

C3 AND C4 APPLY SPRING ASSEMBLY V09526.00.00

Figure 13.

The former and current C3 and C4 reaction plates, pistons, housings, piston return plates are not interchangeable. All
former C3 and C4 components have been maintained for service. Service WTEC II and III transmissions with the former
C3 and C4 reaction plates, piston return plate, clutch housings, pistons, and apply spring assemblies. Service Allison 4th
Generation controls transmissions with the current C3 and C4 reaction plates, piston return plate assembly, clutch
housings, and pistons. As stated earlier, the Allison 4th Generation controls C3 and C4 clutch configuration does not use
an apply spring assembly.

RETARDER VALVE BODY ASSEMBLIES

The Allison 4th Generation Controls system includes redesigned retarder valve body assemblies, which consist of a
redesigned valve body, retarder control solenoid, internal valves, springs, separator plates, etc. Allison 4th Generation
controls retarders all use a common regulation spring; retarder capacity is controlled by TCM calibration. Figure 14
illustrates the differences between the former and current retarder valve body assemblies.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 29 of 38

4 2

5 27 15

30 6 23
7 16
10 17
2 8 18 19
9
11 3
19 29
12 20
13 21 22
STARTING WITH 21
18 22 28
S/N 6510262246 14 20
3 4
2 23 13
1 9 12 5
10 6
14 26 11 7
25 1 8
15 16
17 24
PRIOR TO
S/N 6510262246 FORMER CURRENT
WTEC III ALLISON 4TH
GENERATION CONTROLS
3000 PRODUCT FAMILY

3
2
25 4 5
6
3 4 7
9 8
1 5 28
27
7 6 2
10 30
8 29
10 11
9 11 12 31
13 12 13

14 26
22 28 1 25
21 27 14
23 21
26
24 24
15 16 15
17 16
18 17 23
19 18 20
20 19 22
21

FORMER CURRENT
WTEC III ALLISON 4TH
GENERATION CONTROLS
4000 PRODUCT FAMILY

RETARDER VALVE BODY V09532.00.00

Figure 14.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 30 of 38

Table 7. Former WTEC III 3000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Gasket, Separator Plate. Used Prior to 6510262246. See SIL 13-WT-00. 29535940 1
2 Plate, Solenoid Separator. Used Prior to 6510262246. See SIL 13-WT-00. 29529294 1
2 Plate, Solenoid Separator. Used Starting With 6510262246. When Replacing 29537643 1
29529294 Solenoid Separator Plate With 29537643 Solenoid Separator Plate,
Discard Two 29535940 Separator Plate Gaskets. See SIL 13-WT-00.
3 Gasket, Separator Plate. Used Prior to 6510262246. See SIL 13-WT-00. 29535940 1
4 Body Assembly, Retarder Control 29529311 ** 1
5 Wiring Harness, Solenoid Assembly 29529313 1
6 Connector, Mold, Retarder Feedthrough 29528584 1
7 O-ring, 31.5 mm ID 29529486 1
8 Connector Assembly, 2-Way Plug 29528597 1
9 Connector, Solenoid 29541590 1
10 Terminal, Female 12124639 2
11 Solenoid 29537373 1
12 O-ring, 17.2 mm ID 23016455 1
13 O-ring, 12.4 mm ID 23014057 1
14 Valve, Retarder Control 29530445 1
15 Spring, Low 29529300 1
15 Spring, Medium 29529299 1
15 Spring, High 29529298 1
16 O-ring, 16.4 mm ID 23019664 1
17 Plug 29534508 1
18 Pin, Retainer 29500823 1
19 Plug 29534508 1
20 O-ring, 16.4 mm ID 23019664 1
21 Valve, Relay 29530446 1
22 Spring, Relay 29529310 1
23 Body, Retarder Control 29535632 1
24 Plug Assembly, Pressure Tap 29500034 1
25 O-ring, 8.9 mm ID 23043446 1
26 Plug, Pressure Tap 29541018 * 1
27 Clip, Spring 29538484 1
28 Bolt, M8 x 1.25 x 40 29535636 3
29 Bolt, M8 x 1.25 x 60 11515368 6
30 Cover, Retarder Connector 29536988 1

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 31 of 38

Table 8. Current Allison 4th Generation Controls 3000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Plate, Solenoid Separator 29542891 1
2 Body Assembly, Retarder Control 29542987** 1
3 Body, Retarder Control 29542986 1
4 Valve, Relay 29542573 1
5 Spring 29529310 1
6 Plug Assembly, Straight Thread 29542780 1
7 O-ring, 16.4 mm ID 23019664 1
8 Plug, Straight Thread 29534508 1
9 Plug Assembly, Straight Thread 29542780 1
10 O-ring, 16.4 mm ID 23019664 1
11 Plug, Straight Thread 29534508 1
12 Spring 29529310 1
13 Valve, Regulator 29542572 1
14 Pin, Retaining Solenoid 29542996 1
15 Solenoid and Connector Assembly, Variable Bleed 29542516 1
16 Solenoid, CENL, Variable Bleed 29544298 * 1
17 Seal, Square Cut O-ring 29543047 1
18 O-ring 29544645 1
19 Bolt, M8 x 1.25 x 65 29542988 9
20 Plug Assembly 29500034 1
21 O-ring, 8.9 mm ID 23043446 1
22 Plug, Pressure Tap 29541018 * 1
23 Cover, Retarder Connector 29536988 3

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
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October, 2005
Product Code(s): 65, 66
Page 32 of 38

Table 9. Former WTEC III 4000 Product Family

REF
NO. NOMENCLATURE PART NO. REQ
1 Bolt, Flange Hd, M8 x 1.25 x 100 mm 11515115 9
2 Valve Body Assembly, Retarder Control 29536991 ** 1
3 Bolt, Flange Hd, M8 x 1.25 x 55 mm 29510680 5
4 Wiring Harness 29503939 1
5 Cover, Solenoid 29511063 1
6 Gasket, Solenoid Cover 29511062 1
7 Solenoid, N/C 29537373 1
8 O-ring, 16.9 mm ID 23016455 1
9 O-ring, 12.2 mm ID 23014057 1
10 Stop, Valve 29538569 1
11 Spring, 7.8 mm OD x 29.2 mm 23049391 1
12 Valve, Exhaust Backfill 23049320 1
13 Valve, Retarder Control 29511060 1
14 Body, Valve, Retarder 29536989 1
15 Pin, Dowel, 2.5 mm x 40 mm 29500823 1
16 Pin, Dowel, 3 mm x 43 mm 29500822 1
17 Spring, 15.09 m OD x 33.69 mm 29512792 1
18 O-ring, 23.6 mm ID 23015806 1
19 Plug, Straight Thread, M27 x 2.0 29536990 1
20 Not Used In This Group
21 Gasket, Separator Plate 29512744 2
22 Plate, Separator 29511057 1
23 Plate, Channel 29511055 1
24 Gasket, Channel Plate 29507891 1
25 Cover, Retarder Connector 29519205 1
26 Plug Assembly, Pressure Tap 29500034 1
27 O-ring, 8.9 mm ID 23043446 1
28 Plug, Pressure Tap, 7/16-20 29541018 * 1

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
October, 2005
Product Code(s): 65, 66
Page 33 of 38

Table 10. Current Allison 4th Generation Controls 4000 Product Families
REF
NO. NOMENCLATURE PART NO. REQ
1 Plate, Separator 29542569 1
2 Cover, Retarder Connector 29536988 1
3 Valve Body, Assembly, Retarder Control 29542381 ** 1
4 Plug Assembly, Straight Thread 29542780 1
5 Plug, Straight Thread 29534508 1
6 O-ring, 16.4 mm ID 23019664 1
7 Spring, 7.8 mm OD x 29.2 mm 23049391 1
8 Valve, Exhaust Backfill 29542492 1
9 Solenoid and Connector Assembly, Variable Bleed 29542516 1
10 Solenoid, CENL, Variable Bleed 29544298 * 1
11 Seal, Square Cut O-ring 29543047 1
12 O-ring 29544645 1
13 Valve Body, Retarder Control 29542571 1
14 Pin, Solenoid Retaining 29542491 1
15 Valve, Regulator 29542572 1
16 Spring, 12.19 mm OD x 38.15 mm 29529310 1
17 Plug Assembly, Straight Thread 29542780 1
18 O-ring, 16.4 mm ID 23019664 1
19 Plug, Straight Thread 29534508 1
20 Plug Assembly, Straight Thread 29542780 1
21 O-ring, 16.4 mm ID 23019664 1
22 Plug, Straight Thread 29534508 1
23 Spring, 12.19 mm OD x 38.15 mm 29529310 1
24 Valve, Relay 29542573 1
25 Gasket, Retarder Control Valve Cover 29542493 1
26 Cover, Retarder Control Valve 29542494 1
27 Bolt, Flange Hd, M8 x 1.25 x 30 mm 29537513 3
28 Plug, Assembly, Pressure Tap 29500034 1
29 O-ring, 8.9 mm ID 23043446 1
30 Plug, Pressure Tap, 7/16-20 29541018 * 1
31 Bolt, Flange Hd, M8 x 1.25 x 115 mm 29542495 9

* Serviced Only As An Assembly—Not Available As A Detail Part.

** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
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Product Code(s): 65, 66
Page 34 of 38

For 3000 Product Family transmissions, Allison Transmission has introduced the following redesigned retarder valve
body components for Allison 4th Generation Controls systems:
• Retarder valve body
• Variable bleed solenoid and connector assembly
• Retarder Regulator valve and spring
• Retarder Relay valve
• Separator plate
For 4000 Product Family transmissions, Allison Transmission has engineered many of the Allison 4th Generation
Controls retarder valve body components to be common with the 3000 Product Family. For example, the two product
families use the same variable bleed solenoid and connector assembly, and both have common retarder regulator valves,
relay valves, and springs. Additionally, the 4000 Product Family retarder valve body is made from cast aluminum and
sized to eliminate the need for a separate channel plate. The following is a list of redesigned retarder valve body assembly
parts for Allison 4th Generation Controls 4000 Product Family transmissions.
• Retarder valve body, gasket, and cover
• Variable bleed solenoid and connector assembly
• Retarder regulator valve and spring
• Retarder relay valve and spring
• Retarder exhaust backfill valve
• Rubber coated separator plate
The former and current retarder valve bodies, solenoids, electrical connectors, separator plates, valves, springs, and stops
are not interchangeable. All former 3000 and 4000 Product Families retarder valve body assembly components have been
maintained for service. Service WTEC III transmissions with the former retarder valve body components. Service Allison
4th Generation controls transmissions with the current retarder valve body components.
RETARDER ACCUMULATORS
The Allison 4th Generation controls system includes resized retarder accumulators. The former accumulators have been
maintained for service. The former and current retarder accumulators are not interchangeable. Use the former retarder
accumulators to service WTEC II and III transmissions and use the current retarder accumulators to service Allison 4th
Generation controls transmissions. Refer to the following table to determine retarder accumulator assembly part numbers.

WTEC II and III Controls Allison 4th Generation Controls

Assembly Accumulator Assembly Accumulator
Number Volume Number Volume
3000 Product Family accumulator 29535963 1.25 liter 29544597 0.90 liter
4000 Product Family accumulator 29535964 0.60 liter 29544646 0.50 liter

New to Allison 4th Generation controls, the retarder accumulator solenoid will remain OFF when RMR device retarder
request percentage is less than 20 percent. Additionally, the retarder accumulator solenoid will not activate when torque
requested is less than 343 N·m (253 lb ft) for 3000 Product Family retarder and 374 N·m (276 lb ft) for 4000 Product
Family retarder transmissions. This is intended to enhance retarder regulator valve and relay valve operation at low
retarder request percentages. Figure 15 shows the detail parts for the current Allison 4th Generation 3000 Product Family
retarder accumulator. Figure 16 is the current Allison 4th Generation 4000 Product Family retarder accumulator detail
parts. Tables 11 and 12 identify the parts in Figures 15 and 16, respectively.
 15-WT-05, Rev. A
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2
8

1
9

10

7
11
3
12
13
4

V06140.03.00

Figure 15.

Table 11. Current Allison 4th Generation 3000 Product Family Accumulator
REF
NO. NOMENCLATURE PART NO. REQ
1 Accumulator Assembly, 3000 Product Family, Solenoid and Cylinder 29544597** 1
2 Accumulator Assembly 29544596** 1
3 Seal, Lip, WT 29527008 2
4 SLYD Ring, WT 29527009 1
5 Piston, WT 29527007 1
6 Body, Cylinder 29544595 1
7 Bolt, Tie Rod 29544594 4
8 Cap, Cylinder End (Hydraulic) 29534487 1
9 Seal, End Cap 29534489 2
10 Cap, Cylinder End (Gas) 29534488 1
11 Valve Assembly 29544455 1
12 Nipple 443981 1
13 Solenoid 29544456 1
** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
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Product Code(s): 65, 66
Page 36 of 38

2
8

1
9

10

7
11
3
12
13
4
14
5

V06140.02.00

Figure 16.

Table 12. Current Allison 4th Generation 4000 Product Family Accumulator
REF
NO. NOMENCLATURE PART NO. REQ
1 Accumulator Assembly, 4000 Product Family, Solenoid and Cylinder 29544646** 1
2 Accumulator Assembly 29544648** 1
3 Seal, Lip, WT 29527008 2
4 SLYD Ring, WT 29527009 1
5 Piston, WT 29527007 1
6 Body, Cylinder 29544649 1
7 Bolt, Tie Rod 29544647 4
8 Cap, Cylinder End (Hydraulic) 29534487 1
9 Seal, End Cap 29534489 2
10 Cap, Cylinder End (Gas) 29534488 1
11 Valve Assembly with Nipple (P/N 29514765) 29544809 1
12 Nipple 443981 1
13 Solenoid 29544456 1
14 Nipple Assembly 29514765 1
** Not Serviced As An Assembly—Order Detail Parts.
 15-WT-05, Rev. A
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Product Code(s): 65, 66
Page 37 of 38

J1939 COMMUNICATIONS
Common functions

• Accelerator Pedal • Range Displays—“Range Attained”

• Accelerator Pedal Kickdown • Range Inhibited Indicator

• Auxiliary Function Range Inhibit—Single Input • Reverse Warning

• Cruise Control, Standard • Retarder Temperature Indicator

• Cruise Control, via Engine PTO Governor • Road Speed Limiting

• Direction Change Enable • Secondary Mode Indicator

• Driveline Retarder Capacity Reduction • Service Brake Status

• Neutral Start • Sump Temperature Indicator

New and Improved functions

Accelerator Pedal–Remote—Oil Field Special units can receive a second J1939 accelerator pedal input.
Anti-Lock Brakes (ABS)—The Allison 4th Generation Control system now responds to torque limiting messages from
the ABS controller prior to receiving a notification from the engine controller that ABS is active. This allows the TCM
to coordinate Retarder response prior to and during an ABS event.
Automatic Traction Control (ATC)—When wheel spin occurs, the vehicle’s traction controller may request reduced
engine torque and active vehicle braking systems to redirect power to drive wheels with traction. The Allison 4th
Generation Controls system is fully able to interpret engine output reductions from traction controllers versus throttle
pedal position.
“Check Trans” Indication—The Allison 4th Generation Controls system can signal a vehicle dash lamp controller to
activate the “Check Trans” light.
Driveline Retarder Control—Retarder enable switch is no longer required to be hard-wired to the TCM when retarder
activation is accomplished via J1939.
Diagnostic communications with Allison Tools—High speed CAN 2 connection available for twice as fast
communication.
Driveline Retarder Control—Can be fully controlled via J1939.
Driveline Retarder Capacity Reduction—Improved retarder torque control during temperature-related retarder
capacity reductions.
Electronic Brake Systems (EBS)—Improved retarder accuracy (may required pressure feedback sensor).
Engine Compression or Exhaust Brakes—Can now support vehicle installations with multiple (2) engine brakes, i.e.
one compression brake and one exhaust brake.
Engine Management (SEM and LRTP)—Improved torque control coordination with approved engines. Two types of
torque control messages exist: Shift Energy Management (SEM) and Low Range Torque Protection (LRTP). Engine
OEMs must implement SEM and LRTP together.
Neutral Start—Faster signal response results in improved functionality.
 15-WT-05, Rev. A
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Page 38 of 38

Oil Level Display—Three new parameters have been added to the transmission fluids message. Vehicle OEMs may
duplicate the oil level readout in the Allison shift selector. The information is only sent when selector is in ‘oil level
display’ mode.
Range Displays—‘Requested Range’—Revised message format to permit OEMs to recognize commonly used Allison
shift selector status, i.e. ‘flashing’ or ‘blank’ display.
‘Retarder Active’ Indicator—Can now activate vehicle brake lights, etc via J1939.
Secondary Mode Input—Can now activate secondary shift schedule via J1939 message. If used, will override analog
wire input for secondary mode.
Shift Selector, J1939-Based Allison Manufactured—Supports all functionality of the WTEC III selector, including
range, oil level and diagnostic displays. Pulse Width Modulated (PWM) ‘back-up’ wire required.
Shift Selector, J1939-Based Customer-Supplied—Supports all functionality except diagnostic displays. PWM
‘back-up’ wire is optional. Use requires a ‘special’ calibration in addition to a legal agreement between Allison
Transmission and the OEM.