2013 Thomas C2 skipping gears, high revving, and erratic shifting / downshifting – Allison Transmission issues?
Hey everyone,
I’m driving a 2013 Thomas Built Saf-T-Liner C2 and I’ve been dealing with a really frustrating issue since early March. Like most of us, I work a split shift (morning and afternoon runs).
The issue mostly happens during my afternoon run. Right after starting the bus and taking off, the engine revs incredibly high because the automatic transmission refuses to upshift. After driving for about a mile, it usually clears up and acts normal.
However, it’s getting worse. Now it happens dynamically during the route, even after the bus has been driving fine for a while. When accelerating from a stop, it feels like the transmission completely ignores 2nd gear. The bus struggles to get moving, the engine revs like crazy until I hit about 25 mph, and then it feels like it slams straight from 1st into 3rd gear. After that, it drives fine again.
Even stranger is what happens when I'm coasting. As soon as I let off the gas and my speed drops below 30 mph, the engine suddenly screams and the RPMs shoot up to around 2500 RPM. If I were to compare it to a manual transmission car, it feels exactly like someone dumping the clutch while keeping their foot on the gas—the engine just roars, even though I'm not touching the throttle.
The weirdest part is that it’s completely intermittent. It can happen three days in a row, and then nothing for three weeks. It almost never happens during the morning run, mostly in the afternoon (maybe a thermal/heat-related issue?). Also, I'm not alone: just today, I saw a coworker leaving the yard in the exact same C2 model, and her bus was screaming and revving high just like mine.
Another critical detail: I noticed that the transmission temperature gauge seems to be completely "frozen" at around 160°F. It never goes any higher, even when the engine is screaming at 2500 RPM and putting massive stress on the transmission. Could the TCM be stuck in a limp mode due to a faulty TFT (Transmission Fluid Temperature) sensor or a wiring harness issue, causing it to use a default substitute value and mess up the shift points?
I have written this up in my DVIR three times now and even talked to our head mechanic face-to-face. All I got was a "I'll look into it," but nothing has been done—which is unusual for our shop since they usually make us sign off on every little repair.
Has anyone experienced this before? Could this be faulty input/output speed sensors, a sticking solenoid pack, or a TCM issue? Any advice or bullet points I can hand over to my shop to get them moving would be greatly appreciated!
Just to be clear: I am not a mechanic, I am just the driver. After dealing with this for weeks, you honestly start second-guessing yourself and wondering if you suddenly forgot how to drive a bus, or if there is actually a mechanical failure. I definitely don't want to tell our shop how to do their job, but I just want to understand if this is a real technical issue so I can prove I'm not just losing my mind.
Thanks!