Fullbay’s 2026 Report: Heavy-Duty Shops Face Structural Technician Shortage

Why It Matters

The technician shortage threatens the scalability of a booming heavy‑duty repair market, forcing shops to compete on culture, benefits, and technology to sustain growth.

Key Takeaways

• Record $5.04B service revenue in 2025, 68% growth
• Technician wages up 14% to $36.50/hr, outpacing inflation
• 54% shops report understaffing; median technician age 41
• AI tools used by 35% shops; diagnostics top interest
• Culture outranks pay for retention, 49% prioritize respect

Pulse Analysis

The latest Fullbay State of Heavy‑Duty Repair report shows that independent shops are thriving despite broader freight softness. In 2025 shops processed $5.04 billion in service orders and generated an additional $1.5 billion in parts revenue, delivering a 68 % net new revenue gain since 2023. This surge is driven by an aging truck fleet that stays on the road longer, creating higher demand for complex repairs. Improved freight rates have also pulled idle equipment back into service, giving shops more work and reinforcing their role as a critical link in the logistics chain.

That growth, however, is being squeezed by a structural technician shortage. Median labor rates climbed 10 % to $149 per hour, while technician wages jumped 14 % to $36.50 per hour—far outpacing inflation. More than half of surveyed shops reported understaffing, and the median technician is 41 years old, with only 17 % under 30. Retention now hinges on workplace culture rather than pure pay; 49 % of technicians rank respect and recognition above compensation. Shops that offer transparent bonuses and clear career paths enjoy a 26‑point hiring advantage.

Technology is beginning to offset the talent gap. Thirty‑five percent of shops have adopted artificial‑intelligence tools, primarily ChatGPT, to streamline diagnostics and customer communication, and 61 % plan to use AI for predictive maintenance. Larger shops are leveraging higher parts margins—up to 21 %—to fund benefits and training programs that attract skilled labor. For fleets, rising maintenance budgets and tighter labor markets mean they must partner with shops that can deliver fast, reliable service while offering competitive compensation packages. The report warns that without a concerted effort to train the next generation, the shortage could intensify, threatening long‑term industry sustainability.