Navistar is working on a number of capability insertions for the International MaxxPro Dash. This vehicle includes an independent suspension system intended to improve off-road mobility in Afghanistan.
The MaxxPro Dash returns from a trip around the off-road track at the UK Ministry of Defence's DVD Show in June 2009.
MaxxPro MRAP vehicles sit in the 532nd Expeditionary Security Forces Group Quick Response Force parking area at Joint Base Balad, Iraq, 7 October 2008.
US Army soldiers from Bravo Company, 1st Battalion, 6th Infantry Regiment (assigned to Task Force 1-35 Armor, 2nd brigade combat team, 1st armoured division) conduct a mounted patrol in MaxxPro MRAP vehicles after setting canal vegetation ablaze in Tahwilla, Iraq, on July 30, 2008.
1st Lieutenant Andrew Schlaf, the fire support officer for Company B, 1st Battalion, 35th Armor Regiment, Task Force 4-27 "Thunder", 2nd brigade combat team, 1st armoured division, multi-national division - Baghdad, directs a MaxxPro MRAP vehicle onto a temporary bridge in the Jabour area, south of Baghdad, on 15 December.

MaxxPro MRAP Armoured Fighting Vehicle

Navistar’s MaxxPro is a mine-resistant ambush protected (MRAP) armoured fighting vehicle. Designed to endure improvised explosive device (IED) attacks and ambushes, MaxxPro can withstand ballistic arms fire and mine blasts. The International MaxxPro variant can survive in nuclear, biological and chemical environments. Navistar has delivered more than 9,000 MaxxPro vehicles.

MaxxPro MRAP vehicle mission variants

Navistar came up with a number of mission variants for the MaxxPro vehicle to feature a range of armouring levels and suit the mission requirements. The variants in the MaxxPro series include MaxxPro, MaxxPro Plus, MaxxPro ambulance, MaxxPro MEAP, MaxxPro Air Force and MaxxPro Dash.

The MaxxPro MRAP expedient armour programme (MEAP) offers increased protection among the MRAP vehicles. MaxxPro Plus offers increased explosively forged projectiles (EFP) protection. MaxxPro Dash was designed to be a more mobile and lighter variant equipped with a certain degree of protection.

MaxxPro Dash offers a smaller turning radius and a higher torque-to-weight ratio, which thereby increases the mobility of the vehicle. As it is designed to navigate through rough terrains, MaxxPro Dash is less prone to roll-over problems and is therefore suitable for deployment in Afghanistan.

“Navistar has delivered over 9,000 MaxxPro vehicles.”

Navistar has also developed other recovery MRAP utility variants, which include MaxxPro Wrecker, MaxxPro Cargo and MaxxPro Tractor. These variants have been developed to support the recovery efforts in Iraq and Afghanistan.

The Wrecker MRAP accommodates a crew of two to three men and carries out support missions such as retrieving damaged or mission-disabled vehicles.

All variants of the MaxxPro vehicle have increased supportability and maintainability, and feature a high degree of part commonality.

MaxxPro armoured vehicle orders and deliveries

Four MaxxPro vehicles were initially tested at the Aberdeen Proving Grounds in March 2007. Following this, the US Marine Corps ordered 1,200 units on 31 May 2007 for delivery by February 2008. The contract was worth $623m.

On 19 June 2007, the US Marine Corps awarded an $8.5m contract to provide 16 MRAP vehicles by the end of September 2007. Another 755 MRAP vehicles were ordered on 23 July 2007 for delivery by February 2008 in a contract worth an estimated $414m.

The US Marine Corps awarded a further contract on 18 October 2007 for the supply of an additional 1,000 MaxxPro units by April 2008, worth approximately $509m.

“Navistar’s MaxxPro Dash is less prone to roll-over problems and is therefore suitable for deployment in Afghanistan.”

On 18 December 2007, the US Marine Corps awarded Navistar a contract for the delivery of 1,500 MRAP units in a contract worth an estimated $1.2bn. Navistar was awarded an additional contract on 17 March 2008 for the delivery of another 743 MRAP units to the US Marine Corps, which was valued at more than $410m. By March 2008, Navistar had delivered 2,000 MRAP units to the military.

Another $752m contract was awarded to Navistar on 4 September 2008 for the delivery of 822 MaxxPro Dash units by February 2009. The delivery of all 822 units was completed by the end of January 2009, one month ahead of schedule. On 10 September 2008, Navistar delivered the 5,000th MRAP vehicle to the US Marine Corps.

On 10 December 2008, the US Military awarded another contract worth around $362m to Navistar Defense, for the delivery of 400 MaxxPro Dash vehicles to meet urgent requirements in Afghanistan operations.

On 16 February 2010, a $752m contract for 1,050 MaxxPro Dash vehicles was awarded to Navistar by the US Marine Corps Systems Command. The deliveries concluded by mid 2010. The MaxxPro Dash vehicles supplied under the contract included the DXM independent suspension solution provided by Hendrickson Truck Suspension Systems and AxleTech International. The new upgrade increases the vehicle’s off-road capabilities, necessary for operations in Afghanistan.

In November 2010, the US Marine Corps placed a $253m order for 250 MaxxPro Recovery vehicles. Another order for 175 MaxxPro Dash vehicles with DXM independent suspension was placed in December 2010.

Navistar received a $183m order from the US Marine Corps in May 2011 to deliver 250 MaxxPro Dash ambulances equipped with DXM independent suspension. The US Marine Corps placed a $357m order for an additional 471 MaxxPro Dash vehicles with DXM independent suspension in June 2011.

In July 2011, the US Marine Corps placed a $142m order for 140 MaxxPro recovery vehicles with rocket-propelled grenade (RPG) nets. A $134m order for field service representatives (FSRs) was placed by the US Marine Corps Systems Command in December 2012. Navistar was awarded a $110m contract by the US Marine Corps Systems Command in January 2012 to supply 650 independent suspension kits for MaxxPro Plus MRAP vehicles.

In September 2012, Navistar was awarded a $282m contract to supply over 2,300 survivability upgrade retrofit kits for MaxxPro Dash MRAP vehicles of the US Army.

MaxxPro MRAP vehicle design and features

The MaxxPro vehicle incorporates the design of a crew capsule with a V-shaped hull, which is mounted on the Navistar International model 7000 chassis. The purpose of the V-hull is to deflect the blast of either a land mine or an IED away from the vehicle. The incorporation of such a design has enabled MaxxPro to survive a 7kg (15lb) land mine blast without any injuries.

The vehicle can use standardised and readily available parts to ensure rapid repair and maintenance. The armoured body of the vehicle is bolted together and not welded, which facilitates on-field repairs.

“MaxxPro can survive a 7kg (15lb) land mine blast without any injuries.”

MRAP vehicles are classified into two categories – Category I or Category II – based on their usage and the number of passengers that can be accommodated. MaxxPro Dash is a lighter, more mobile version of the Category I or mine-resistant utility vehicle (MRUV) and offers increased commonality among parts for easier integration. It is a smaller and lighter-weight vehicle among the variants and maintains the same survivability as the other variants.

The mobility of the vehicle has been improved through smaller turning radius and a higher torque-to-weight ratio. Additional uparmouring can also be accommodated in this variant. Supportability and maintainability of the vehicle is maximised.

MaxxPro Plus is an upgraded MaxxPro vehicle featuring performance and survivability enhancements, increased payload and additional engine performance. MaxxPro Wrecker, MaxxPro Cargo and MaxxPro Tractor are built on Navistar’s WorkStar platform and have a MaxxPro Dash cab.

The MaxxPro variants can accommodate two crew members, four to six passengers and a gunner.

MaxxPro MRAP vehicle engine

MaxxPro uses the MaxxForce D8.7I6 engine while MaxxPro Plus and MaxxPro Dash use model D9.3I6 of the MaxxForce D family of engines. The engines are manufactured by Navistar International Corporation under the brand MaxxForce.

“MaxxPro Plus and Dash can accept add-on armour as per the mission requirements.”

The D9.3I6 is a turbo inter-cooled, direct electronic injection, four-stroke engine. Built on I-6 architecture, it offers a performance similar to larger, heavy-duty engines and at the same time provides the economy of a medium-duty diesel engine.

The engine uses a low-pressure fuel supply pump. It has a generation-two electro hydraulic fuel system, which includes an under-valve-cover oil manifold, fuel injectors and a high-pressure oil pump.

Additional engine strength is provided by a crankcase and bearing ladder cap, whereas the single-piece steel pistons and six head bolts per cylinder secure a longer engine life.

MPAP vehicle armament and defence

The MaxxPro is capable of and ready for an explosively formed penetrator (EFP), rocket-propelled grenade (RPG) and remote weapon system or station (RWS). The vehicle is equipped with ballistic protection – armour and glass protection required to meet the mission needs. It can also withstand ballistic arms fire, nuclear, biological and chemical environments.

The V–shaped hull design protects the vehicle against mines or IED blasts. MaxxPro Plus and Dash have been designed to accept add-on armour as per the mission requirements.

The Global Armoured and Counter-IED Vehicles Market 2011-2021

This project forms part of our recent analysis and forecasts of the global armoured and counter-IED vehicle market available from our business information platform Strategic Defence Intelligence. For more information click here or contact us: EMEA: +44 20 7936 6783; Americas: +1 415 439 4914; Asia Pacific: +61 2 9947 9709 or via email.