Tactical Vehicle MaxxPro

Tactical Vehicle MaxxPro

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.


MaxxPro Plus M1234

On June 16, 2008 Navistar debuted a new version called MaxxPro Plus. MaxxPro Plus has increased engine power and payload, as well as Frag Kit 6 enhancements for increased explosively formed penetrator protection.

MaxxPro Dash M1235

On September 4, 2008 the U.S. Marine Corps awarded Navistar a $752 million contract to develop and produce a lighter, smaller, and more mobile MaxxPro variant that is less prone to the rollover problems that have plagued MRAP vehicles. MaxxPro Dash M1235A1 has a smaller turning radius and higher torque to weight ratio. Production of the MaxxPro Dash began in October 2008 with delivery of 822 units completed by February 2009.

MaxxPro Dash DXM M1235a1

MaxxPro Dash with improved DXM suspension system.

MaxxPro Dash DXM Ambulance

On May 5, 2011 Navistar Defense received a $183 million delivery order for 250 International MaxxPro Dash ambulances with DXM independent suspension.

MaxxPro XL

The MaxxPro XL is a Category II MRAP version of the MaxxPro. It is a larger and longer version of the base vehicle. Because it is longer, it has three bullet-resistant windows on each side, instead of two. The MaxxPro XL can carry up to 10 soldiers.


There is also an MRAP Recovery Vehicle; 250 have been ordered. These are well suited to recovering other vehicles which have been damaged by IEDs.

On July 18, 2011 Navistar Defense received a delivery order for an additional 140 MRV’s with rocket-propelled grenade (RPG) nets from the U.S. Marine Corps Systems Command.


At Association of the United States Army 2013, a version called the Mission Command on the Move (MCOTM) was displayed as a command post with monitors, computers, and antennae mounted in the back for communications and surveillance. Five passengers can monitor incoming information, see unmanned aerial vehicle feeds, and keep track of where units are operating. The vehicle has an on-board transmission-integrated power generator that can produce up to 120 kilowatts of exportable power, which eliminates the need for a towed trailer and can single-handedly power a semi-permanent tactical operations center. It would allow commanders to be connected to dismounted troops and headquarters while on the move. The MCOTM version will undergo testing at the Army’s network integration evaluations in February 2014.


Mass CAT I:
28,000–29,500 lbs (12.7–13.4 t)
30,000–32,000 lbs (13.6–14.5 t)
Length 21.17–23.5 ft (6.5–7.2 m)
Width 8.25 ft(2.5 m)
Height 10 ft (3 m)
Crew 3-7

Engine 9.3L, 570 cubic inches MaxxForce D9.3I6 I6
330 hp @ 2,100 rpm; 375 hp in Plus and Dash variants
Power/weight 18.9–20 hp/US ton
Payload capacity 3,650–11,150 lbs (1.6–5 t)
Transmission Allison 3000 5-speed automatic
Suspension 4×4, wheeled semi-elliptical leaf springs
Ground clearance 14″ (0.35 m)


  • Afghanistan —155 with 15 MRAP recovery vehicles will be in service with Afghan National Army. As of February 2015, 10 have been received.
  • Algeria – used by the special forces, 116th Operational Maneuvers Regiment (116e RMO) 
  • Albania – 38,used by the Special Operations Battalion
  • Bulgaria – 4 in service with the Bulgarian Army, all deployed in Afghanistan
  • Croatia 35 in service with Croatian Army, 5 with Croatian contingent in Afghanistan. In April 2014, the US Army donated 30 MRAP MaxPro to the Croatian Army.
  • Czech Republic – used by Czech army in Afghanistan.
  • Georgia
  • Egypt – 12 MaxxPro MRAP Recovery Vehicles (MRV)
  • Hungary 42 MaxxPros in service, with the last 12 received in September 2013. 12 more loaned to the Hungarian Army on 26 November 2013 for training.
  • Iraq used by Iraqi special operations forces
  • Jordan 100 MaxxPros in service with JAF
  • Lithuania – Used by special forces in Afghanistan
  • Nigeria – In service from 2016.
  • Pakistan – 325 MaxxPro MRAPs of different versions in service with the armed forces , and an additional 37 Maxx pro MRV is service as well .
  • Poland – 30 MaxxPro in service in Afghanistan with the Polish Land Forces since September 2010 on ACSA terms, then MaxxPro Dash
  • Portuguese Army – all deployed in Afghanistan.
  • Romania – 60 MaxxPro Dashes in service in Afghanistan with the Romanian Land Forces
  • Slovakia – Donated to the Slovakian Army by the United States.
  • Singapore – 15 MaxxPro Dashes in service with Singapore Army, deployed in Afghanistan as part of NATO-led International Security Assistance Force.
  • South Korea 10 MaxxPro Dashes in service with Republic of Korea Army, deployed in Charikar, Afghanistan under “Ashena” unit, as part of International Security Assistance Force.
  • Syrian Democratic Forces
  • Turkey – MaxxPros donated from the US Army are deployed in Afghanistan.
  • Yemen – Dozens of Maxxpros were donated to the Yemeni national army and scores others to the Yemeni national resistance forces by the UAE.
  • United Arab Emirates – 3,375 MaxxPros of various versions on order.
  • United States
  • North Macedonia – 55 retired, replaced with BTR-70/80, BMP-2 and MT-LB.
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