This guide covers full fluid capacities for all Allison 4000 series models, plus explanations, maintenance intervals, and helpful notes every owner or mechanic should know.
Allison 4000 Transmission Fluid Capacity
| Transmission Model | Transmission Type | Sump Type | Drain & Refill Capacity | Total Dry Fill Capacity |
|---|---|---|---|---|
| Allison 4000 | HD Automatic | Standard | 26–29 quarts (6.5–7.25 gal) | 47–51 quarts (11.75–12.75 gal) |
| Allison 4000 | HD Automatic | Deep | 30–33 quarts (7.5–8.25 gal) | 51–55 quarts (12.75–13.75 gal) |
| Allison 4000MH | Motorhome | Standard | 26–29 quarts | 47–51 quarts |
| Allison 4000MH | Motorhome | Deep | 30–33 quarts | 51–55 quarts |
| Allison 4000RDS | Rugged Duty Service | Standard | 27–30 quarts | 48–52 quarts |
| Allison 4000RDS | Rugged Duty Service | Deep | 32–34 quarts | 52–56 quarts |
| Allison 4500 | HD Automatic | Standard | 27–30 quarts | 48–52 quarts |
| Allison 4500 | HD Automatic | Deep | 32–34 quarts | 52–56 quarts |
| Allison 4500RDS | Rugged Duty | Standard | 27–30 quarts | 48–52 quarts |
| Allison 4500RDS | Rugged Duty | Deep | 32–34 quarts | 52–56 quarts |
| Allison 4700 | HD Commercial | Standard | 28–31 quarts | 48–53 quarts |
| Allison 4700 | HD Commercial | Deep | 32–35 quarts | 52–57 quarts |
| Allison 4800 | HD Extreme | Standard | 29–32 quarts | 49–54 quarts |
| Allison 4800 | HD Extreme | Deep | 33–36 quarts | 53–58 quarts |
Related Check Allison Transmission Fluid Level(Step by Step)
Understanding Allison 4000 Fluid Requirements
Why Fluid Capacity Matters
Unlike smaller automotive transmissions, the Allison 4000 handles extreme torque loads, heavy hauling, constant stop-and-go cycles, and continuous power takeoff (PTO) operations. Running on low fluid or incorrect fluid can cause:
- Overheating
- Gear slipping
- Harsh or delayed shifting
- Premature clutch wear
- Transmission failure
Given the large capacity, up to 58 quarts – even small errors in fluid levels can significantly impact performance.
Related Allison Transmission Fluid Capacity Chart(All Models)
Recommended Fluid for Allison 4000 Series
Allison recommends TES 668 or TES 295 synthetic fluids for best protection, including:
- Allison TranSynd®
- Approved TES-295/TES-668 equivalents
These fluids offer:
- Extended drain intervals
- Better thermal stability
- Superior clutch protection
- Lower oxidation
Service Types and How Much Fluid You Actually Need
Allison transmissions have three common service types:
1. Drain & Refill
Only about 50–65% of total fluid is removed.
- Standard sump: 26–30 quarts
- Deep sump: 30–34 quarts
2. Full Fluid Exchange
Uses the cooler return line to replace almost all fluid.
- Requires near total dry fill capacity: 48–58 quarts
3. Dry Fill (Rebuild or New Transmission)
Only required after full overhaul or new installation.
- 47–58 quarts depending on model & sump
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Standard vs. Deep Sump Differences
The 4000 Series is commonly equipped with either a standard pan or deep pan.
Standard Sump
- Lower fluid carrying capacity
- Better ground clearance
- Common in highway trucks & buses
Deep Sump
- Improves cooling
- Reduces fluid degradation
- Ideal for towing, construction, off-road, and RV motorhomes
Deep sumps increase capacity by 4–6 quarts on average.
How to Check Allison 4000 Transmission Fluid Level
Most Allison 4000 transmissions use electronic fluid checks via the shift selector:
- Park on level ground
- Transmission in neutral
- Parking brake applied
- Fluid at normal operating temperature (140–220°F)
- Press the appropriate fluid check buttons (varies by shifter)
The display will show:
- oL = oil level
- oK = level correct
- Lo = add fluid
- HI = too much fluid
Related Automatic Transmission Fluid Color Chart(All Colors)
Allison 4000 Fluid Change Intervals
| Fluid Type | Typical Change Interval |
|---|---|
| TES 295 / TES 668 Synthetic | 150,000–300,000 miles |
| Conventional ATF | 25,000–50,000 miles |
| Severe Duty | Change intervals cut by 50% |
Signs You Need to Change Allison 4000 Transmission Fluid
Look for:
- Increased operating temperature
- Dark/burnt smell of fluid.
- Rough shifts
- Reduced performance
- Fluid contamination
- Trouble codes related to clutch performance
Early service prevents expensive downtime.
Common Mistakes When Filling an Allison 4000 Transmission
Avoid:
- Overfilling – leads to foaming and overheating
- Mixing incompatible fluids
- Using automotive ATF instead of Allison-approved fluid
- Ignoring the sump type
- Not running the engine during level checks
FAQs
What is the capacity of the Allison 4000?
The Allison 4000 Series transmission capacity varies depending on the model and sump type. Standard sump models typically hold 26–31 quarts for a drain-and-refill service, while deep sump models may require 30–36 quarts. For a full dry fill after a rebuild or new installation, capacities range from 47 to 58 quarts.
How much transmission fluid goes in an Allison transmission?
The amount depends on the service type:
- Drain & refill: 26–36 quarts, depending on sump and model.
- Full fluid exchange: 48–58 quarts.
- Dry fill (new or rebuilt transmission): 47–58 quarts. Always check your specific model and sump type before filling.
What kind of fluid does an Allison 4000 take?
Allison 4000 transmissions require Allison-approved fluids, typically TES 668 or TES 295 synthetic transmission fluids. TranSynd® is also recommended for long life, high thermal stability, and superior clutch protection. Standard automotive ATF or Dexron-type fluids should not be used.
What is the service interval for the Allison Transmission 4000?
Service intervals depend on fluid type and duty:
- TES 295/TES 668 synthetic fluids: 150,000–300,000 miles under normal duty.
- Conventional fluids: 25,000–50,000 miles.
- Severe-duty operations, such as construction, city buses, or motorhomes, require more frequent service, often reducing intervals by 50%.
Can I use Dexron VI in Allison transmission?
No. Dexron VI or other standard automotive ATFs are not compatible with Allison 4000 transmissions. Using the wrong fluid can cause poor shift quality, clutch damage, and premature failure. Always use Allison-approved TES 668, TES 295, or TranSynd® fluid.
Final Thoughts
The Allison 4000 Series transmission is built for extreme durability, but proper fluid levels and high-quality synthetic ATF are critical to keeping it performing at its best. With capacities ranging from 26 to 58 quarts, understanding your exact model and sump configuration ensures you always fill it correctly.
Use the table above whenever servicing a 4000, 4000MH, 4000RDS, 4500, 4500RDS, 4700, or 4800 transmission to guarantee accurate capacity and long service life.
