Description

Allison 4560, 4500 2016 Parts Catalog

If you’ve spent time chasing down the wrong part number for an Allison 4560 or 4500 transmission, you know the headache. Aftermarket catalogs cut corners. One wrong assembly number means a torque converter that doesn’t fit, or a clutch kit that’s for the wrong sump. The Allison 4560, 4500 2016 Parts Catalog fixes that. This is the factory document — 323 pages of Allison’s own part breakdowns. No translation errors, no guesswork.

ReTran Assembly Numbers for 4560 and 4500 Variants

You get the actual 4500(P)RM ReTran assembly numbers used to service transmissions like the 4560(P), 4500 EVS, 4500 HS, 4500 RDS, and 4500 SP — all without a retarder. The manual tells you to use Group 15-512 for wide ratio transmissions. It also lists tachograph rear covers (39-588, 39-702, 39-764, 39-821, 39-823, 39-854, 39-857) so you match the right housing to your build. Each assembly number cross-references specific sump and clutch combinations. You don’t guess; you pick the right line.

Torque Converter Specs and Clutch Kits

Two torque converter families are covered: TC 551 (numbers 21-767, 21-927) and TC 561 (21-768, 21-926). Clutch options break down by TID1/TID2 Raybestos clutches (01-750) and TID3 Dynax clutches (01-807). Each clutch kit is tied to a sump configuration and PTO provision. If you need to order a rebuild set, the catalog gives you the exact Allison part number. No aftermarket cross-reference that may or may not be right.

Sump Configurations and Oil Level Sensors

Transmissions come in 4-sump or 2-sump versions, with or without an oil level sensor. The catalog lays out each combination: for example, a 4-sump with oil level sensor, PTO provision 34-545, lists assembly numbers 16-1601, 1602, 1639, 1640, 1700, and 1701. A 2-sump without sensor uses different numbers. Keep it straight. One wrong sump pickup means you starve the clutches.

PTO and Non-PTO Provisions: What Fits Your Build

Every transmission variant is sorted by whether it has a PTO provision (34-545) or a non-PTO provision (34-543). Some builds require the wrap-around slinger; others don’t. The catalog tells you which rear covers (e.g., 39-545, 39-701, 39-820, 39-853) work with each. If you’re retrofitting a 4560 into a chassis that needs side PTO, you need these numbers. Aftermarket lists merge everything into one blob. This catalog respects the differences.

Why OEM Documentation Matters for Safe Repairs

You wouldn’t use a generic torque spec on head bolts, so don’t rely on generic parts data. Allison designed these transmissions with specific clearances, materials, and assembly orders. A wrong clutch pack or incorrect sump gasket can cause internal leaks, overheating, or catastrophic failure. This manual lets you verify every component before you order. Safety on a dyno starts with correct parts. Don’t let a skipped cross-reference cost you a transmission.

Who Needs This Manual?

DIY mechanics pulling a 4500 for a rebuild. Shop owners who want to stock the right clutches for common jobs. Fleet managers maintaining buses or RVs with Allison 4000-series boxes. Even a beginner who’s following a factory rebuild order will benefit from having the OEM part numbers open on the bench. You don’t need to be a transmission specialist — you need the right data. Related manuals for other Allison torque converters include Allison TC 200-300 TCA TCRD 200 1976 Parts Catalog, Allison 200, 300 1967 Parts Catalog – OEM Torqmatic Parts, and Allison TC 200, TC 300, TCA 200, TCA 300, TCRD 200 1971 Parts Catalog. For broader context on automotive transmission evolution, see Automotive Industry Overview and Automotive Industry Overview.

Does this catalog cover the Allison 4560 with a retarder?

No. The ReTran assembly numbers listed are for transmissions without a retarder. For retarder-equipped units, you need the separate retarder section of the catalog.

What years are covered?

This is a 2016 publication, so it reflects parts and assembly numbers current at that time. Always check with Allison for supersessions after 2016.

Are torque converter bolt patterns included?

Bolt patterns are not listed in this parts catalog. It focuses on assembly numbers, sump configurations, and clutch part numbers. For torque converter dimensions you need the service manual, not the parts catalog.

How many pages and what format?

323 pages in the original PDF. You get the full factory document, not a scan of a reprint. Assembly numbers for TC 551 and TC 561, TID1/TID2 and TID3 clutches, sump and PTO options — all there. Page count helps you estimate printing cost if you want a hard copy, but the digital version is searchable.

Stop flipping through aftermarket listings that don’t match. Get the real factory parts catalog for your Allison 4560 or 4500 transmission. Access the Factory Manual from AutoRepairManuals and have the correct assembly numbers on your bench.