The 44-year-old announced that she would make her highly-anticipated return to the Cobbles earlier this year and speculation about her arrival back in Weatherfield has been rife.
Details of her upcoming storyline are being kept tightly under wraps, but Alison has revealed that her character will come back harbouring a huge secret.
Carla will return to see her brother Aidan Connor (played by Shayne Ward) as he desperately tries to save Underworld.
However, it seems that the bombshell is back for her family, over business, and initially refuses to get involved in the lingerie factory again.
But fans of the ITV soap will learn that the secret she is holding close to her chest makes her more vulnerable.
Alison teased: “She is at a stage where she is starting to think about life and family, her secret is making her take stock. In the past two years she has acquired a family that she didn’t know she had.
“Prior to that she was a bit of a lone wolf, she had people like Michelle around her but suddenly she had a family that she does really care about, they mean a lot to her.
“This is a different Carla because of the secret she is keeping so the next few months we will see a more vulnerable Carla who needs her family and friends more than she ever has before.”
What’s more, it appears the only person who knows about her secret is Roy Cropper (David Neilson).
“Roy is always there for Carla,” Alison explained. “He is the one person who knows her secret and he is the one person she has confided in.”
“He has always been a father figure. He could be the key to her sticking around.”
Coronation Street continues tonight on ITV at 7.30pm and 8.30pm.