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Powering Bold Possibilities: A Modern Delivery Platform

We believe that if it can be imagined, it can be created. When a leading commercial vehicle manufacturer needed to integrate a modern powertrain into a new delivery vehicle, they turned to Roush. By combining the customer's visionary design with our deep expertise in systems integration, calibration, and emissions certification, we transformed a complex engineering challenge into a road-ready reality. Together, we co-imagined and co-created a 50-state certified, highly durable fleet solution, proving that bold ideas are only as powerful as their real-world performance.

What was the challenge?

The customer faced a monumental integration hurdle. They wanted to install a light-duty powertrain—complete with an all-wheel-drive system and transmission—into a large, heavy, aerodynamically challenging commercial delivery van.

This mismatch resulted in a very low power-to-weight ratio. The vehicle’s unique duty cycle of frequent, low-speed stop-and-go driving demanded aggressive and highly creative powertrain controls changes to ensure acceptable performance, long-term durability, and compliance with the strictest EPA and CARB tailpipe and evaporative emissions standards. The customer needed a nimble, solution-agnostic partner who could absorb the execution risk and deliver end-to-end engineering.

Roush was the perfect partner for the project. The goal was clear: take a visionary concept and engineer it into a fully certified, durable, and highly efficient production vehicle.

What did we accomplish?

End-to-End Powertrain Integration
We love to create that which does not yet exist. Over the course of 24 months, our core team of engineers and technical specialists dedicated approximately 130,000 engineering hours to the program. We successfully navigated four distinct prototype phases, building and testing five initial mule vehicles, seven validation prototypes, three design confirmation vehicles, and four pilot production units.

Custom Hardware & Fabrication
Every great solution is built on engineering with deep knowledge and uncompromising detail. Our team designed and fabricated numerous custom components specifically for the testing and development of this heavy-duty application. This included custom front suspensions, steering components, transmission mounting, half-shafts, exhaust systems, and fuel lines. We also fabricated prototype aerodynamic pieces to simulate frontal area drag, ensuring the vehicle’s cooling systems could handle the intense thermal demands.

Advanced Calibration & Diagnostics
To address the low power-to-weight ratio and grueling drive cycle, we modified hundreds of unique calibration parameters. We adjusted the engine’s peak torque curve to deliver exceptional powertrain durability. We also designed and implemented a brand-new evaporative system leak diagnostic within the powertrain control software to ensure full OBDII compliance.

Rigorous Real-World Testing
We thrive on the “challenge us” spirit. We conducted over 540 calibration and emissions tests and pushed the hardware through extreme durability cycles. The engine survived over 1,300 hours combined of fatigue and wear testing. The transmission endured 5,200 hours of dynamometer testing, completing the equivalent of three consecutive Key Life Tests, executing over 600,000 shifts. When we discovered the massive delivery vehicle was too tall to fit into standard North American evaporative emissions test cells, our Midwest get-it-done attitude kicked in: we simply removed the roof of the test vehicle to make it fit and get the data we needed.

130,000
total engineering hours dedicated
19
prototype vehicles built and tested over 4 phases
700
calibration parameters modified
30%
tailpipe emissions performance measured to be 30% below the maximum allowable levels as established by EPA and CARB requirements.

What services were provided?

The customer needed a partner capable of handling every element of powertrain development under one roof. We provided comprehensive hardware design, advanced powertrain calibration, rigorous durability testing, and full regulatory certification services.

By leveraging our deep vertical integration—utilizing our dedicated emissions labs and powertrain dynamometer facilities—we kept the project moving rapidly. Even when external supply chain delays threatened the schedule, our team adapted the timing plan and delivered every key milestone on time.

What is the impact?

The partnership between Roush and this major vehicle manufacturer proves that collaboration and teamwork applied to complex problems can yield elegant solutions and high-performing results.

Through relentless testing and creative calibration, we signed off the vehicle’s tailpipe emissions at just 70% of the maximum EPA and CARB mandated standards. The final product successfully met all regulatory requirements for certification across all 50 US states.

For the customer, the partnership accelerated their path to production and secured a highly reliable powertrain for a demanding commercial fleet application. For Roush, the project reinforces our position as the ultimate execution partner for advanced mobility. We stand agile, capable, and prepared to take on the industry’s greatest engineering challenges.

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