By late 2007, the military was getting reports from Iraq that Cougar axles were bending or breaking when driven off-road, possibly to avoid mined routes. Each vehicle can cost $1 million, counting equipment - a hefty sunk cost.
A search for solutions led to the independent suspension system, and that led to a $158 million contract for the manufacturer to supply the kits now being installed in Kuwait as the vehicles leave Iraq.
Marines who have driven the revamped version like it, said Kim Yarboro, a civilian manager of the Cougar program. "If you wanted to take them through a harsher environment - unimproved roads, cross-country, rocky or hilly areas - you could do that with an independent suspension and have a better ride quality," she said.
One recent morning, a tan Cougar sat atop a hill on a 4.4-mile course that is laced with curves and sharp inclines. The Cougar resembled a Tonka truck on steroids, with its huge grill and 4-foot-tall tires. Inside were seats for 10 people, including the driver.
Independent suspension
Test driver Pat Hamilton has logged many miles in the original fixed-axle Cougar and the newer version with the independent suspension. He said both he and his kidneys greatly prefer the latter model.
"It's like a Honda Civic versus a Cadillac ride," he said. "It cushions the ride so much better."
Hamilton turned on the ignition, bringing the truck to life with a deep growl. With the push of a button in the cab, he changed the tire inflation from a hard-surface setting to cross-country. Air hissed as it left the tires, giving the rubber a better grip on the dirt-gravel road.
Then it was time to show what the Cougar could do.
Four times Hamilton drove the same loop - downhill at an 18 percent grade, a sharp turn to the left, then an uphill climb. In the span of perhaps a quarter-mile, the road heaved with some 20 bumps. He took the first pass at a relatively slow clip, 25 mph or so, before increasing his speed on subsequent runs.
"I'm hitting this pretty hard; we're running almost 30 miles per hour," Hamilton said after taking the Cougar airborne. The truck rattled as it landed, but for occupants it was a smooth experience.
"You would not do that in the previous model," he said, laughing. "It would just be a rough ride. You would be wanting to beat me up."
