JA SPRDL122C0060_Redacted.pdf

SPRDL1-22-R-0067 (JA-00495)

Previous J&A is not available

5. Reason for Authority Cited:

This differential is a critical component of the PLS fleet. Power from the vehicle’s engine is transferred along a path through the transmission, driveshaft, differential, and finally transferred to the wheels which drives the vehicle forward and backward. The differential uses a series of gears and clutch plates to multiply and distribute the torque output of the engine and provide that energy to the axles. Without it, the power generated by the engine cannot be transferred to the wheels. This differential has been specifically integrated with the PLS’s drivetrain in mind, which makes it unique among other commercially procurable transmissions. The differential is a Meritor product, and the Government does not own or have rights to any of the detailed technical data. Not having the technical data means the number of gears, gear ratios, load rating, and other criteria used to qualify this item cannot be easily compared with other commercially available transmissions. Selecting an alternative that may not meet performance specifications would be detrimental to mission capability, as well as readiness. The burden of risk associated with using an unsuitable differential is too great; so, this Gear Assembly, Speed Reducer must be procured from Meritor.

The Ground Vehicle Systems Center (GVSC) Vehicle Sustainment Team has calculated that Reverse Engineering the PLS A1 Differential Assembly would cost an estimated minimum of $3,200,000 with a lead time of at least 48 months that would be comprised of:

- Research and Development (R&D), including part design, development, and production

- Reliability, Availability, and Maintainability (RAM) testing, including qualification and vehicle integration testing

- Technical Data Package (TDP) development, in order to procure competitively

- Establishing additional sources

The Vehicle Integration and Qualification testing requires allocating a donor vehicle, fit-up of the differential assembly, minimum number of miles driven on a test track, and post-test wear evaluation.

Action Time Cost Reverse-Engineer

Differential 18 months $2,000,000.00

Qualification Testing 12 months $1,000,000.00

Develop TDP 6 months $200,000

Validate Additional Source 12 months -

Total Development 48 months $3,200,000.00

SPRDL1-22-R-0067 (JA-00495)

Previous J&A is not available

Keyword: industrial differential Website: https://www.aam.com/what-we-do/our-technologies/tracrite

The differential product lines available from Eaton and American Axle were reviewed for comparison. The information provided on these websites was not sufficient to determine if they would serve as a suitable direct replacement for the current differential assembly provided by the OEM Meritor used on the PLS. With the TDP and unique performance specifications being unavailable, it becomes extremely difficult to ensure compatibility.

Many manufacturers make differentials that, at first glance, seem similar to the one used for this application. Comparing features such as load rating, power input/input, gear ratios, and physical size do not provide enough detailed information to justify their use. This particular differential has undergone validation testing by Meritor to ensure its safety and performance for this application. It has been carefully integrated to work in tandem with the current engine and driveline configuration unique to the PLS. The result of selecting a potential alternative that was not specifically designed and tested for this application is an elevated risk of issues in the future. These issues will negatively impact maintenance, readiness, and ultimately soldier safety if a failure were to occur during operation.

If the technical information for the differential on the PLS was made available, it would allow for more specific market research and potentially allow for competitive procurement to be an option.

Meritor has verified that this item, PN A86015445 is currently valid and procurable.

The Contract Specialist performed web-based market research on May 17, 2022, and determined this Gear Assembly, Speed Reducer is a commercial item pursuant to FAR Part subpart 2.101 – Definitions. The Gear Assembly, Speed Reducer being procured by this action may have limited applications, but speed reduction gear assemblies, in general, have a wide variety of applications in the commercial marketplace. The Item Manager concurred with this assessment on May 18, 2022.

9. Interested Sources: To date, no additional sources have expressed interest in this item.

10. Other Facts: Procurement History:

Contract Number: SPE7L3-20-V-3907 Award Date: 4/20/2020 Contractor (CAGE): HDT Vehicle Component Sales (1SER6) Contract Value: $ 18,795.43 Competitive Status: Unknown - Columbus contract file inaccessible