Ever wondered what it takes to turn an old Light Medium Tactical Vehicle (LMTV) into a state-of-the-art Acela Monterra? We sat down with Acela Truck and learned exactly what it takes to make a work truck that can go anywhere and get the job done.

Check out the complete photo gallery for a comprehensive guide that walks you through the steps involved and shows the dedication and craftsmanship that go into each Acela Monterra truck.

Whether you're a fleet manager, mechanic, or just curious about the process, this behind-the-scenes look will give you a new appreciation for these rugged vehicles.

Upgrading the Hydraulics: Safety First

The transformation starts with a crucial safety upgrade. The original air-over hydraulic cab tilt  systems in each LMTV are swapped out for electric-over hydraulic systems. The original manifold had a high failure rate.

The Acela team decided to reengineer this problem part. This change makes it safer for the team to work on the trucks and provides easier access to the engine, fixing the issues of the old, unreliable system.

Conducting A Thorough Mechanical Inspection

Next, the trucks head to the mechanics bay for a thorough 300-point inspection. The expert Acela mechanics use the latest diagnostic equipment to scan major components, identifying any issues that need fixing.

This is where true mileage and hours of use are pulled from. Many military trucks have speedometers swaped during their use in the Military. By using the CAT ET system the team is able to understand what is truly happening with the engine as well as true hours of use and true mileage.

Mechanical problems are addressed, and sub-standard parts are replaced. All rubber seals and hoses are replaced.  

If a truck has too many issues, like a cracked engine block or a transmission issue, it is used for parts to ensure the quality of the remaining fleet. If the chassis passed the rigorous vetting process it is now a candidate for the reset process. This is also when the chassis will have all of it’s seals replaced, axles rebuilt, and charging system upgraded.

Tear Down: Preparing for Overhaul

After passing inspection, trucks enter the Tear Down phase. This involves disassembling the truck for a complete overhaul.

The cab and nearly all frame-mounted parts are carefully removed, inspected, and cataloged. These parts are then sent to specialized shops for further breakdown and refurbishment.

Painting and Rehabilitation

In the paint phase, each cab is stripped down to the sheet metal. Seals, doors, electrical harnesses, and other components are removed. Using advanced body repair and painting techniques, the cabs and chassis are rehabilitated to look and perform better than new.

This meticulous process ensures every part meets high standards.

Reassembly: Bringing It All Together

Once the components are refurbished, the Reassembly phase begins.

New hoses, belts, seals, and gaskets are installed. Parts are inspected against strict ATC and OEM guidelines, and any out-of-specification components are replaced. Cabs are outfitted with new interiors, including seating, insulation, electronics, and digital instrumentation.

Final Assembly: The Finishing Touches

During Final Assembly, the cab is reattached to the chassis, and all fluids are replaced with OEM-certified ones. Wheels are rebuilt and mounted with new tires, and over 600 parts are replaced. This phase ensures the truck is ready for performance testing and final quality checks.

Performance Testing: Ensuring Top Performance

Before delivery, each Monterra undergoes rigorous performance testing. Critical settings like torques, clearances, and pressures are adjusted and recorded. The truck then goes through a series of quality assurance, diagnostic, and road tests to ensure it meets the highest standards.

Shipment and Delivery: Ready for the Road

Once fully assembled and tested, each Monterra is shipped to or picked up by the customer. Every truck comes with a one-year limited warranty and is supported by the AcelaCare program, which ensures timely delivery of parts and maintenance support.

After following each phase of this transformation process, the dedication and precision that goes into creating a Monterra is clear. It's not just about turning an old vehicle into a new one; it's about ensuring reliability, safety, and performance for every truck that rolls off the production line.

Standard in every Acela Monterra:

• Full Commercial Interior – Noise and Heat Dampening Insulation, Commercial Headliner, Interior Lighting

• Air Conditioning

• Upgrade Charging System

• Upgraded Electric Over Hydraulic Cab Tilt and Spare Tire Carrier

• Air-Ride Seating

• Power Heated Mirrors

• Full Time All-Wheel-Drive

• Touchscreen Stereo

• USB Power Ports

• New Door Handles

• New Tires & Wheels

• CAT ET Diagnostic Report

• New Alternator

Standard Options:

• Proprietary High-Water Fording Kit

• Third Passenger Center Seat

• Back-up Camera

• Back-up Alarm

• Rebuilt Central Tire Inflation System

• High Speed Gearing – Regears from 55 to 68 mph.