MaxxPro run flat inserts. Built for MRAP-class armor, one insert per corner.
The MaxxPro was built to take the hit and keep rolling, and every corner of every truck runs on a run flat insert. The Toota Group supplies segmented antiballistic polymer inserts built to NSN 2640-01-563-1421 as an alternate item — field-serviceable, quoted and built to order. CAGE 93ST9. We are not the approved source of supply; we are the alternate.
Armor designed to take the hit — wheels that have to keep rolling.
The MaxxPro was built for survivability: V-shaped hull, armored crew capsule, and wheels expected to keep the vehicle moving after a blast or ballistic strike. Every one of those outcomes depends on what happens at the wheel end. When a tire loses air, the run flat insert becomes the load path — and on an MRAP, that load path carries thousands of pounds of armor per corner.
- MRAP-class loads — inserts support 5,000+ kg per corner on armored platforms
- Holds the bead — the deflated tire stays seated at speed and under maneuver
- Blast and ballistic duty — engineered for IED fragments, strikes, and terrain damage
- Fleet-wide impact — one kit configuration serves MaxxPro, Cougar, and Buffalo A2
Total air loss, bead seated — and the truck keeps rolling through the village. The Toota Group insert under load.
Alternate Item — NSN 2640-01-563-1421
- NSN: 2640-01-563-1421
- Platforms: MaxxPro, Cougar, Buffalo A2 (per DLA end-item data)
- Material: Antiballistic segmented polymer
- Install: Standard shop equipment, no special rig
- Reusability: Segments inspect and re-use
- Weight: ~15% lighter than solid rubber
See the system work.
The system in motion — and the product itself, ready to ship.
A MaxxPro rolling through a rain-soaked street on a destroyed tire — the run flat insert carries the load. Our render of the system in action.
Static RunFlat for multi-piece wheel assemblies.
Three pieces beat the solid ring.
Solid one-piece inserts need a hydraulic press to fit, degrade from heat during run-flat operation, and often end up single-use. Segmented polymer changes the math for a motor pool:
| Factor | Segmented Polymer (ours) | Solid One-Piece Insert |
|---|---|---|
| Weight per wheel | ✓ ~15% lighter — less unsprung mass | Heaviest option |
| After a deflation event | ✓ Inspect, swap damaged segments, re-use | Heat degradation — often replace whole insert |
| Deployment logistics | ✓ Segments stack flat, ship lighter | Bulk shipping, heavy handling |
The grease is part of the system.
During run-flat operation the tire tread rides directly on the insert, and heat is the enemy. Purpose-built run flat grease keeps friction and heat down through the mobility window — in the same NSN line the fleet already buys: tube NSN 2640-01-419-6200 (one per tire at installation) and 55-gallon drum NSN 2640-01-457-5552 for fleet-level maintenance programs.
What a Fleet Order Looks Like
- Insert kit: NSN 2640-01-563-1421 (1 per wheel)
- Lubricant — pick ONE: tub (52 oz), tube NSN 2640-01-419-6200, or 55-gal drum NSN 2640-01-457-5552
Alternate item for the MaxxPro run flat.
The Toota Group is an alternate source for this NSN configuration — same fit, same function — production tooling ready to build.
Spec the MaxxPro insert on your next buy.
Tell us your variant mix and quantity. We'll confirm the configuration and quote — built to order, quote direct.