Luckyme I bought a bus

[GFREE]

Great forum, looking forward to learning and contributing. I am a retired gearhead who enjoys working on old trucks, cars, bikes and now buses.
Somehow I got myself a 2002 TC FE 4800 Blue Bird. It has a 132.0 inch wheelbase, 74 inches of headroom,

5.9 ISB 24V.Cummins (limited to 2300 rpm?) and an Allison AT545 4 speed bolted to a 4.78 diff.

I'm happy "crusing" along at 50mph/80km, however, I am concerned that some road raging maniac will curse my existence for driving this city bus on the hyway.
What is the Best solution to get my speed up to normal hyway speeds of 60-70mph (100 -110 km/h)?
Apparently I have a J190 w 4.78 ratio
1. I might be able to get my hands on a 3.91.
2. I have read that I could possibly increase the rpm, although not favorably by sliding the fuel plate and/or housing forward wo causing a run-away...
3. Possibly finding an unlocked 6 speed MD3060 trans that will bolt upto the 5.9 Cummins' Bell.
Looking forward to hearing from anyone who might have some insight into this issue.
I don't want to cause any grief to the professional drivers who are just trying to make a living by slowing them down.

 

[magnakansas]

Allison 545 is sae3 bellhousing and a 3000 series will be #2 bellhousing. Look up on the back of the engine. See if you have an adapter ring. If you put in a 6 speed - keep the rear gear you have for now. I have a 4.3 rear gear and I don’t think I could use a six speed. But also have 10r22.5 tire.

Fuel plate? I don’t think a 24 valve has a fuel plate. From the very very little I think I know. The 24 valve is program limited to rpm. You, I think, have an industrial computer and is not the same as a dodge pickup.

William

 

[nikitis]

From what I've read on here, the 4.7 range and slightly higher is the best for 6th gear usage. It works fine on 4.3 as well. The 3.x's you likely won't ever make use of 6th gear or it will shift back promptly once you enter it. I personally would stick with the rear gear you have as well. I have a 4.78 as well with an AT545, but I'm a mid- 90's bus on J1708. So it's harder and more expensive for me to upgrade due to electrical wiring nightmare. Since you're on J1939, the electrical shouldn't be a problem. Just plug and play. Hardware is your only concern with a swap as Magnakansas stated above. You (maybe) have to also have ECM flashed to change Transmission type from MT to AT so the engine knows what's up as the AT545 is all mechanical, so a MT (Manual transmission). I know in my case I have to change it to AT if using the AU translation device from J1708 to J1939, so you may have to as well, but not 100% on that factoid, just be prepared that you may have to have dealership flash that value.

 

[GFREE]

I want to express my sincere appreciation for your prompt and informative responses. They have really helped clarify my options, and I now feel more inclined to consider changing the transmission rather than adjusting the gear ratio.
I also want to mention that the bus starts up quickly and runs smoothly, so I’d prefer to keep the engine as is without any modifications to the governor or other component
I am looking forward to researching the mechanical and electrical requirements of replacing the AT545 with a AT3000 series 5 speed.
I have just started reaching out locally to see what is available and what the best options are to make the bus more highway worthy.
I am thinking that I may need to find the appropriate forum feeds rather than rambling beyond the newby introduction.
Thank you again for efforts and insights. I am very much looking forward to embracing this lifestyle and participating in this forum.

 

[nikitis]

This post was just made to do what you are looking to do. Worth a read. I asked him if he could document what he did, and he was awesome in doing so.

@AzironaZack
AT545 to AT1000

Now this is for an AT1000, but switching to a AT3000 isn't much different. Consider the parts mentioned like torque converter, flywheel adjustments and SAE adapter ring for the AT3000 so it mounts properly to your engine. Wiring would be similar as both are J1939 transmissions. There are differences, but much of what you have to go through is the same.

 

[La Camioneta]

Find an A2000 series out of a later-model school bus. A lot of guys go for the 6 speed, but at .64-.61 OD never get into 6th due to lack of horsepower.

This is a pretty good reference: Spicer Transmission Ratio RPM Calculator

You'll need this guy: Allison 6-speed Swap

Cheap used trans can be gotten from scrapped Ford 6.0PSD buses, but be mindful of the torque converter. Cummins wants a TC-222 White tag, which is the lowest rpm converter.

Converter Stall Speed – Transmission Tuner

transmissiontuner.com

As far as increasing power, well that's up to you, there is huge potential for 5.9's!

 

[GFREE]

Thanks for the awesome insights!
I'm on a mission to get this bus cruising down the highway without cooking the engine and pissing off everyone behind me.

I really appreciate the input, and I know I've got quite a bit of research ahead of me.

On another note, this bus has air assisted On-board sanders and auto tire chains (wheel assisted helicopters). Do I keep them for the rare occasion of using them or do I delete them to save on weight and air burden?

I was also thinking, as I am sure many before me, of using the chairlift for my motorcycle and creating a toy hauler. Any thoughts on this? The lift is good for 800lb and the bike is 500wet

 

[Carl635]

On the left (while sitting in the bus) front of the engine there should be a Cummins tag that states the HP and governed RPM of the motor.....or how it was when stock.

 

[Mr P]

Study up on the engine, it's the 24v Cummins, right? VP44 pump issues are known, and there are "corrective" measures available.

 

[ewo1]

Study up on the engine, it's the 24v Cummins, right? VP44 pump issues are known, and there are "corrective" measures available.

Yes, very good advice!

I have come to learn that the vp44 suffers from long term overheating especially if your like me and drive until the fuel gauge gets to 'E". Something about the lift pump not pushing enough fuel to keep the VP44 happy with heat temperature...

 

[SkyMaster]

That's a beautiful bus and the 5.9 Cummins is one of the best motors out there.

Regarding the trans swap, check out post #4 and #5

7.3 IDI with Allison 1000 overheating

Hey there, folks! I've got a 1991 International 3700 based short school bus with a 7.3 IDI, original injection pump, non-wastegated Banks Turbo, and intercooler. This bus is an RV for me and my wife. I am having trouble with overheating. The radiator, thermostat, fan, and viscous clutch are...

www.skoolie.net

 

[#1FordFan]

I’d keep the chains, you never know when you’ll find soft ground that turns into mud quickly.

 

[nikitis]

I’d keep the chains, you never know when you’ll find soft ground that turns into mud quickly.

^^ This, and it doesn't take much with the weight of a skoolie. I tore up my front lawn trying to park it on the side yard. Thought the grass would toughen up the ground. Nope.... She just sank