ENGINEERING SOLUTIONS

HOMOLOGATION

A major automotive manufacturer chose Roush as their full-service engineering partner to support the homologation and release of a full-size pickup into the South American market. The Roush team assembled for this project included program management, engineering, design, analysis, prototyping, garage services, and development activities to work in concert with a limited OEM engineering and liaison team.

The Roush team took the engineering lead in almost all areas, working with the OEM engineering and manufacturing groups, their core engineering and testing groups, external testing organizations, and all identified suppliers to release all of the vehicle components into the OEM system, pass all OEM criteria, and to homologate the vehicles for the intended market.

Roush also provided plant coordination and support, and attended all North American pilot plant and South American production plant build stages through 90 days past launch. Roush provided similar support at the program’s frame and chassis supplier’s South American locations and other supplier facilities where needed throughout the program.

The vehicle line encompassed 2 different wheelbases, 3 different body styles, 4 engine options, 4 transmissions (auto and manual), and 3 different payload ratings (660, 750, and 1000 kg). The comparatively extreme South American environment required that the entire vehicle to be certified for twice the severity of the initial US vehicle’s 4x4 Heavy Duty durability cycle requirements. Legislative restrictions mandated accommodation of E22 fuel for the gas engines.

As a result of the many governing standards and factors, all vehicle systems (except body sheet metal) were new or revised from the North American truck, including chassis, powertrain, electrical, interior, and glass, and several new South American manufacturers were established in the OEM system to satisfy local sourcing requirements.

The vehicle design, analysis, testing, and development activities were successfully completed within the program objectives and the Roush team was seamlessly integrated into the OEM vehicle development and production process. Ultimately, the production vehicles received critical acclaim from consumers and industry experts.