Grumman LLV

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American light transport truck model

title: "Grumman LLV" type: doc version: 1 created: 2026-02-28 author: "Wikipedia contributors" status: active scope: public tags: ["united-states-postal-service", "postal-history-of-the-united-states", "rear-wheel-drive-vehicles", "trucks", "grumman-vehicles", "postal-vehicles", "vehicles-introduced-in-1986", "vehicles-discontinued-in-1994"] description: "American light transport truck model" topic_path: "history" source: "https://en.wikipedia.org/wiki/Grumman_LLV" license: "CC BY-SA 4.0" wikipedia_page_id: 0 wikipedia_revision_id: 0

::summary American light transport truck model ::

::data[format=table title="Infobox automobile"]

FieldValue
nameGrumman Long Life Vehicle
imageSmall USPS Truck.jpg
captionA 1989 Grumman LLV of the United States Postal Service, seen in Carson City, Nevada in December 2005
manufacturerGrumman
akaUSPS Mail truck
production1986–1994
assemblyMontgomery, Pennsylvania
predecessorJeep Dispatcher
successor
classMail truck
layoutFront-engine, rear-wheel drive
engine
transmission3-speed GM TH180 automatic
wheelbase100.5 in
length175.5 in
width75 in
front_suspension54.1 in
rear_suspension63 in
height85 in
weight2700 lbs
relatedKurbWatt, Kubvan
spus
::

| name = Grumman Long Life Vehicle | image = Small USPS Truck.jpg | caption = A 1989 Grumman LLV of the United States Postal Service, seen in Carson City, Nevada in December 2005 | manufacturer = Grumman | aka = USPS Mail truck | production = 1986–1994 | model_years = | assembly = Montgomery, Pennsylvania | predecessor = Jeep Dispatcher | successor = | class = Mail truck | body_style = | layout = Front-engine, rear-wheel drive | platform = | engine = | transmission = 3-speed GM TH180 automatic | wheelbase = 100.5 in | length = 175.5 in | width = 75 in | front_suspension = 54.1 in | rear_suspension = 63 in | height = 85 in | weight = 2700 lbs | related = KurbWatt, Kubvan | designer = | sp = us

The Grumman Long Life Vehicle (LLV) is an American light transport truck model designed as a mail truck for the United States Postal Service, which has been its primary user since it first entered service in 1986, years ago. It was also used by Canada Post. The LLV uses a chassis built by General Motors based on its Chevrolet S-10 with an aluminum body built by Grumman.

In 2021, after a long competition, the USPS announced it had awarded a $6 billion contract to Oshkosh Defense to produce the Next Generation Delivery Vehicle, which will replace the LLV. In February 2023, the USPS announced the purchase of 9,250 each of stock Ford E-Transit vans and Stellantis gasoline-powered vans. , the first custom NGDVs were scheduled to enter service in June 2024, nine months after the original October 2023 target date.

History

In the United States, the Grumman LLV is the most common vehicle used by letter carriers for curbside and residential delivery of mail, replacing the previous standard letter-carrier vehicle, the Jeep DJ-5. Curbside delivery from a driver seated in a vehicle to a curbside mailbox is sometimes termed "mounted delivery", in contrast to walking delivery.

The Grumman LLV was the first vehicle specifically designed for the United States Postal Service (USPS); the USPS provided a specification and three teams created prototypes that were tested in Laredo, Texas, in 1985: Grumman in partnership with General Motors, Poveco (a joint venture of Fruehauf and General Automotive Corporation), and American Motors Corporation. The main design points of the vehicle in contract competition were serviceability, handling in confined areas, and overall economical operation. Prototypes were each subjected to a 24000 mi road test, including frequent starts and stops, gravel surfaces, cobblestones and potholes, hauling a payload of up to 2000 lb.

Previously, Grumman had built a limited number of KurbWatts, a battery electric vehicle with an aluminum delivery van body, which was tested by the USPS in the early 1980s. At about the same time, Grumman also built 500 KubVans, which used a similar lightweight aluminum delivery body on a Volkswagen Pickup diesel chassis (VW Caddy does not have a separate chassis; it was unibody) and also underwent testing by the USPS. These designs influenced Grumman's candidate body design for the LLV. Grumman won the competition and was awarded a $1.1 billion contract to produce 99,150 LLVs in April 1986; USPS also held an option for an additional 54,000 LLVs.

Production

The vehicles were assembled by the Allied Division of Grumman in Clinton Township in Lycoming County, Pennsylvania. The first vehicle was completed in April 1986. At peak production, 95 LLVs were completed each day, at a rate of approximately one every five minutes. Grumman invested $28 million into the factory, doubling its size to 213000 ft2 and increasing the workforce from 250 to 600.

The USPS purchased more than 100,000 of these vehicles, the last one in 1994. As its name suggests, the Grumman LLV is easily capable of a long life. The required lifespan specified by the U.S. Postal Service was 24 years, but in 2009, this was extended to 30 years. The Grumman LLV can easily last over 200,000 miles on its original engine and transmission before needing an overhaul.

::figure[src="https://upload.wikimedia.org/wikipedia/commons/d/d2/LLV_and_FFV_in_Houston.JPG" caption="FFV]] (right)"] ::

The USPS acquired 21,000 Ford–Utilimaster FFVs in 2000 and 2001 to supplement the LLV fleet. The FFVs have a similar aluminum body and also are right-hand drive, but ride on a chassis built by Ford Motor Company with a body built by Utilimaster.

In 2010, approximately 140,000 LLVs remained in the USPS delivery fleet; retirement and attrition had reduced that to 126,000 by 2021. A number were also sold to Canada, Mexico, and several other countries.

Technical description

Like the older postal-service Jeep DJ-5, the Grumman LLV features a right-hand-drive (RHD) configuration, in contrast to the typical left-hand-drive (LHD) position of vehicles in North America. It also features a large metal tray, which is able to hold three trays of letter mail, mounted where a passenger seat would normally be. This arrangement positions the driver on the side of the vehicle closest to the curb, enabling the carrier to easily grab sorted mail and place it into mailboxes without having to leave the seat. Other notable features are an exceptionally tight turning radius and a low-geared, three-speed transmission for hauling heavy cargo. The LLV has a 1000 lb cargo capacity, double what the Jeep DJ-5 could hold.

The body and final assembly is by Grumman, and the chassis is made by General Motors, based on the 1982 Chevrolet S-10 Blazer, powered by GM engines including the 2.5-liter inline-four TBI Iron Duke and, in later production, 2.2-liter inline-four SPFI LN2; the instrument cluster and front suspension are similar to those used in the Chevrolet S-10 pickup and S-10 Blazer sport utility vehicle.

The LLV has a unique footprint. The front wheels (taken from the two-wheel-drive S-10 Blazer model) have narrower spacing than the rear wheels (using the rear axle from the four-wheel-drive S-10 Blazer model). The front of the vehicle also has low ground clearance. While this has advantages, there are some trade offs. The vehicle was tested successfully in warmer climates, but when used in places with substantial snowfall, they became difficult to control and were poorly adapted to those conditions.

The Grumman LLV's estimated average combined EPA fuel economy is 17 mpgus [16 / on the city/highway cycles, respectively]. In actual use by the USPS, which includes extensive stop-and-go driving for residential delivery, average fuel economy is about 8.2–10 mpgus.

Like other U.S. Postal Service vehicles before it, the Grumman LLV does not carry a license plate and instead uses a seven-digit U.S. Postal Service serial number. The first digit of the serial number represents the last digit of the year in which it was made, ranging from 7 (model year 1987) to 4 (model year 1994). The second and third digits are the vehicle type code, with the LLV's codes ranging from 19-31. The USPS does not permit reselling LLVs, so when they are retired, they are scrapped for parts and the decals are destroyed;

File:Grumman LLV Front.png|Front view of a Grumman LLV File:National Postal Museum (2925193471).jpg|Grumman LLV on display at the National Postal Museum, Washington, DC File:Canada Post LLV.jpg|A Grumman LLV of Canada Post, in Montreal, Quebec in June 2010 File:Grumman LLV Drivers Side.png|Grumman LLV in Concord, NH, in 2017 File:2020_Grumman_LLV.jpg|Grumman LLV in Massachusetts, seen in 2020

Commercial version

Grumman also planned to market a commercial variant of the LLV with right-hand drive as the CLLV through Chevrolet. The CLLV was essentially the same as the LLV, with the same chassis, built by GM at Moraine Assembly using S-10 components, driven by the 2.5L Iron Duke through a 3-speed automatic transmission and a 7-" positraction rear differential with 3.42:1 final drive ratio. The CLLV was rated to carry a payload of 1400 lb, including the driver, and could accommodate up to 121 ft3 of cargo.

Electric versions

Ten LLVs were converted in 1995, 1997, and 1999 for a pilot program, adding a battery electric drivetrain developed by GM Hughes and U.S. Electricar. They used lead-acid battery chemistry. The resulting Electric Long Life Vehicles (ELLVs) were deployed to post offices in Harbor City, California (in Los Angeles); Westminster, California; and Merrifield, Virginia. When GM canceled its electric vehicle program, the vehicles were taken out of service at the end of 2000.

At about the same time, Transport Canada commissioned Solectria Corporation in November 1998 to convert two LLVs to battery-electric; they were delivered to Canada Post in February 1999. The Solectria/Grumman LLV was equipped with a 12 kWh lead-acid traction battery and 5 kW diesel-fired heater, giving it a nominal range of 30 km. The traction motor was an AC induction type, with a peak output of 50 kW and continuous rated output of 20 kW. Testing showed the typical consumption on a postal driving cycle was 19.74 kWh/100km at an ambient temperature of -20 C, giving a range of 27.39 km; these figures improved to 16.04 kWh/100km consumption and 29.58 km range at 20 C. By comparison, the conventionally-powered LLV on the same driving cycle returned fuel consumption of {{#expr:3.31/15.13 round 2}} L/km at -20 C and {{#expr:2.54/15.46 round 2}} L/km at 20 C.

This was followed by a larger fleet test, consisting of 500 Electric Carrier Route Vehicles (ECRV) from 2000 to 2003. The ECRV was equipped with a body similar to the LLV, built by Grumman/Allied on a RHD Ford Ranger EV chassis. Real-world testing at the Fountain Valley, California, post office during July and August demonstrated the average route covered 13–16 mi, consuming an average of 41% of the battery state of charge. After Ford announced they were also canceling their electric vehicle program in October 2002, the battery manufacturer (East Penn Manufacturing Company) offered to sell replacement traction batteries for the ECRVs to be held in cold storage as experience showed the batteries would need to be replaced after two years of service. The USPS instead traded the ECRVs in August 2003 back to Ford in exchange for Windstar minivans.

A second round of testing five converted all-electric LLVs began in 2011. Each second-generation eLLV was converted by a different group, funded by the USPS through a $50,000 grant to each electromodder, and tested in Washington, D.C. By March 2014, only one of the modified eLLVs (from ZAP) remained in service. ::data[format=table title="Second-generation eLLVs"]

Conversion groupLLV No.BatteryTraction motorRangeEfficiencyRef.TypeVoltageCapacityUSPSJ1634Autoport / AC Propulsion / University of DelawareBright AutomotiveEDAGQuantum TechnologiesZAP
2204700Li-Ion375 V60 A-hr
kW-hrAC induction54.4 mi1.16 kWh/mi0.446 kWh/miurl=https://www.energy.gov/sites/prod/files/2014/02/f8/autoportfact.pdftitle=USPS eLLV Conversion by Autoport/AC Propulsion/University of Delaware All-Electric Conversion of the USPS Long Life Vehicle (LLV)website=Energy Efficiency and Renewable Energy Information Centerpublisher=U.S. Department of Energyaccess-date=7 February 2023}}
9216355Li-Ion345 V56.5 A-hr
kW-hrDC brushless47.7 mi0.843 kWh/mi0.503 kWh/miurl=https://www.energy.gov/sites/prod/files/2014/02/f8/brightfact.pdftitle=USPS eLLV Conversion by Bright Automotive All-Electric Conversion of the USPS Long Life Vehicle (LLV)website=Energy Efficiency and Renewable Energy Information Centerpublisher=U.S. Department of Energyaccess-date=7 February 2023}}
8201107Zebra ()371 V150 A-hr
kW-hrDC brushless106 mi1.217 kWh/mi0.598 kWh/miurl=https://www.energy.gov/sites/prod/files/2014/02/f8/edagfact.pdftitle=USPS eLLV Conversion by EDAG, Inc. - USA All-Electric Conversion of the USPS Long Life Vehicle (LLV)website=Energy Efficiency and Renewable Energy Information Centerpublisher=U.S. Department of Energyaccess-date=7 February 2023}}
3300987Li-Ion333 V40 A-hr
kW-hrDC brushless36.9 mi1.063 kWh/mi0.403 kWh/miurl=https://www.energy.gov/sites/prod/files/2014/02/f8/quantumfact.pdftitle=USPS eLLV Conversion by Quantum Technologies All-Electric Conversion of the USPS Long Life Vehicle (LLV)website=Energy Efficiency and Renewable Energy Information Centerpublisher=U.S. Department of Energyaccess-date=7 February 2023}}
8215162Li-Ion267 V80 A-hr
kW-hr3-phase permanent magnet44.1 mi0.939 kWh/mi0.507 kWh/miurl=https://www.energy.gov/sites/prod/files/2014/02/f8/zapfact.pdftitle=USPS eLLV Conversion by ZAP All-Electric Conversion of the USPS Long Life Vehicle (LLV)website=Energy Efficiency and Renewable Energy Information Centerpublisher=U.S. Department of Energyaccess-date=7 February 2023}}
::

;Notes

Replacements

::figure[src="https://upload.wikimedia.org/wikipedia/commons/d/d9/LLV_replacement.jpg" caption="Dodge Caravan Cargo]]) serving in the LLV's role"] ::

Because the United States Postal Service owns more than 100,000 Grumman LLVs, of which most have reached the end of their lifespan, the USPS has been preparing to replace the LLVs. In fiscal year 2009, the USPS spent $524 million to repair and retrofit its fleet of Grumman LLVs, and estimated that it would cost $4.2 billion to replace the entire fleet. By 2021, it was estimated that each LLV required maintenance costing more than $5,000 per year; the all-aluminum body had proven to be robust and corrosion-resistant, but the chassis frame and powertrain components had required reverse-engineering as the original designs were out of production.

The LLVs also suffer from several design deficiencies, including inadequate cabin climate controls (no air conditioning and a heater prone to breaking down). The wheels and suspension are not suited for the all-terrain and all-weather needs of delivering mail and require snow chains during inclement weather. Also, because the windshield washer fluid line is routed above the fusebox, LLVs are prone to catching fire; between 2015 and 2019, over 120 fires occurred. According to documents obtained in 2020 via a Freedom of Information Act request as part of a Vice Media investigation, 407 LLVs have been damaged or destroyed since May 2014.

In some areas, LLVs have been supplemented or replaced with vans and minivans, including the 2008–2010 purchase of Dodge Grand Caravan and Chevrolet Uplander minivans, which tend to be more comfortable for postal workers, especially in extreme climates. The United States Postal Service has announced it would purchase 7,160 Ram ProMaster (to replace Caravan and Uplander vehicles) and up to 30,608 right-hand-drive Mercedes-Benz Metris vehicles as part of the Commercial-Off-The-Shelf (COTS) vehicle program announced on August 3, 2018, to replace and upgrade its fleet of delivery vehicles.

In 2014, the USPS reviewed options for replacement. The Office of Inspector General found that the Postal Service's acquisition plan for replacements lacked details and while the USPS could continue deliveries until 2017, there were concerns over the aging vehicles.

Canada Post also adopted the Grumman LLV, but around 2008, it began studying whether to refurbish, upgrade, or replace its fleet. On March 18, 2010, Canada Post and Ford Motor Company announced that Canada Post would purchase a fleet of Transit Connect vans.

Next Generation Delivery Vehicle

Main article: Next Generation Delivery Vehicle

On January 20, 2015, the USPS released solicitation RFI-NGDV for the Next Generation Delivery Vehicle. Potential bidders had until March 5, 2015, to submit comments and pre-qualification responses. The USPS was to then select companies to receive the RFP for prototype development. On February 13, 2015, it was announced that General Motors was actively pursuing this new contract, which would have them provide the USPS with 180,000 new vehicles at a cost of at least $5 billion. On September 22, 2016, the United States Postal Service awarded the NGDV Prototype Contract to six selected suppliers: AM General, Karsan, Mahindra, Oshkosh, Utilimaster, and a joint-venture bid involving Workhorse and VT Hackney. Half of the prototypes would feature hybrid and new technologies, including alternative fuel capabilities. The prototypes would represent a variety of vehicle sizes and drive configurations, in addition to advanced power trains and a range of hybrid technologies.

On February 23, 2021, USPS announced that Oshkosh Defense was awarded the contract for design and manufacture of the Next Generation Delivery Vehicle (NGDV) to replace the LLV and FFV, delivering up to 165,000 vehicles over a ten-year period.

References

References

  1. "LLV Postal Trucks". Grumman Memorial Park.
  2. Idaho National Laboratory. "All-Electric Conversion of the USPS Long Life Vehicle (LLV)". [[U.S. Department of Energy]].
  3. Gitlin, Jonathan M.. (2023-05-02). "New USPS electric vans delayed until mid-2024, according to court docs".
  4. Shepardson, David. (2023-05-02). "U.S. Postal Service next-generation delivery vehicles delayed to mid-2024". Reuters.
  5. "Restructuring the Postal Service for the 21st Century". postalmag.com (an independent site and is not affiliated with the USPS, its labor unions, or any other postal organizations.).
  6. Hogan, Mack. (December 7, 2019). "This Cute Box on Wheels Is an Ultra-Rare Electric Postal Van From the Gas Crunch". Road & Track.
  7. Niedermeyer, Paul. (March 9, 2011). "KubSide Classic: 1983 Grumman KubVan". The Truth About Cars.
  8. Robert Byrd. (9 April 1986). "Mail van built for long life". [[The Free-Lance Star]].
  9. Singleton, David. (May 13, 1987). "New postal trucks designed to last 24 years". UPI Archives.
  10. Argonne National Laboratory. "Nation's Largest Alternative-Fuel Fleet Delivers the Goods for the U.S. Postal Service". [[U.S. Department of Energy]].
  11. (2023-02-14). "Exactly How Many Miles Does a USPS Mail Truck Last?". MotorBiscuit.
  12. (2007-05-24). "Going the distance: This LLV puts long into life". [[United States Postal Service]].
  13. "2005-01-2675. Application of Digital Human Modeling to the Design of a Postal Delivery Vehicle". [[University of Michigan Transportation Research Institute]]/[[Society of Automotive Engineers]].
  14. (May 2011). "Report to Congressional Requesters: UNITED STATES POSTAL SERVICE: Strategy Needed to Address Aging Delivery Fleet". [[Government Accountability Office]].
  15. (July 11, 2010). ["Long Life Vehicle (LLV)"](https://postalmuseum.si.edu/collections/object-spotlight/long-life-vehicle). [[National Postal Museum]], [[Smithsonian Museum]].
  16. "1988 Grumman Allied Industries LLV". Oak Ridge National Laboratory.
  17. (21 February 2015). "What can stop US Postal Service trucks? The inexorable march of time". The Guardian.
  18. (December 2021). "Final Environmental Impact Statement: United States Postal Service Next Generation Delivery Vehicle Acquisitions". United States Postal Service.
  19. (18 June 2010). "Too Costly to Keep On Truckin?". U.S. Postal Service Office of Inspector General (USPS OIG).
  20. Torchinsky, Jason. (November 2, 2020). "Here's How To Tell The Year Of A Mail Truck Instantly". Jalopnik.
  21. "1991 Grumman LLV Mail Truck VIN#1GBCS10A3M2924002 (TR-3847)".
  22. Acoba, Paulo. (February 25, 2021). "Where can I buy a USPS Grumman LLV Mail Truck?".
  23. (14 January 2016). "CLLV: Commercial Long Life Vehicle (flyer, front page)". Grumman.
  24. Strohl, Daniel. (August 2022). "Lost & Found: Special Delivery?". American City Business Journals, Inc..
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  26. (2014). "Electric Vehicles in the Postal Service". United States Postal Service.
  27. Ryerson, Master and Associates, Inc.. (May 2003). "United States Postal Service Electric Carrier Route Vehicle Program: 500 Vehicle Fleet Deployment Report". United States Postal Service.
  28. (February 2000). "Canada Post Solectria-Grumman LLV Electric Postal Delivery Truck: Comparative Performance Evaluation". Transport Canada.
  29. Southern California Edison. (January 2002). "Demonstration and Evaluation of U.S. Postal Service Electric Carrier Route Vehicles". South Coast Air Quality Management District.
  30. Francfort, James. (January 2002). "Field Operations Program - US Postal Service Fountain Valley Electric Carrier Route Vehicle Testing". Idaho National Engineering and Environmental Laboratory.
  31. (January 9, 2012). "USPS eLLV Conversion Fleet, Reporting period March 11 - Dec 11". U.S. Department of Energy, Energy Efficiency & Renewable Energy: Vehicle Technologies Program.
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  33. "USPS eLLV Conversion by ''Bright Automotive'' {{!}} All-Electric Conversion of the USPS Long Life Vehicle (LLV)". U.S. Department of Energy.
  34. "USPS eLLV Conversion by ''EDAG, Inc. - USA'' {{!}} All-Electric Conversion of the USPS Long Life Vehicle (LLV)". U.S. Department of Energy.
  35. "USPS eLLV Conversion by ''Quantum Technologies'' {{!}} All-Electric Conversion of the USPS Long Life Vehicle (LLV)". U.S. Department of Energy.
  36. "USPS eLLV Conversion by ''ZAP'' {{!}} All-Electric Conversion of the USPS Long Life Vehicle (LLV)". U.S. Department of Energy.
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  38. (September 21, 2017). "Here's What It's Like to Drive a Grumman LLV Mail Truck Every Day".
  39. "Postal Vehicles".
  40. Zwahlen, Cyndia. (May 13, 2019). "Safety Experts Alarmed by Mail Trucks Bursting Into Flames". Trucks.com.
  41. (7 July 2020). "Post Office Delivery Trucks Keep Catching on Fire". Vice.
  42. (14 May 2020). "RHD Mercedes Metris Vans to be deployed to 12,664 rural EMA routes".
  43. (10 June 2014). "Delivery Vehicle Fleet Replacement Report Number DR-MA-14-005". U.S. Postal Service Office of Inspector General (USPS OIG).
  44. link. (2010-07-19 18 March 2010.)
  45. [https://www.fbo.gov/index?s=opportunity&mode=form&id=e4c65069740a6b4df5158fb0a9512b1c&tab=core&_cview=0 "Request for Information and Prequalification/Sources Sought - Next Generation Delivery Vehicle (NGDV) Acquisition Program"] 20 January 2015
  46. (13 February 2015). "Postal service seeks to retire the old mail truck". CNBC.
  47. (16 September 2016). "USPS Statement on Next Generation Delivery Vehicles Prototype Selection and Request for Proposal for Commercial Off-the-Shelf Delivery Vehicles". USPS.
  48. "U.S. Postal Service Awards Contract to Launch Multi-Billion-Dollar Modernization of Postal Delivery Vehicle Fleet - Newsroom - About.usps.com".
  49. Beresford, Colin. (2021-02-23). "USPS Chooses Oshkosh Defense to Replace Its Mail-Delivery Trucks".
  50. (February 23, 2021). "Oshkosh Defense to build U.S. Postal vehicles; Workhorse shares slide".

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united-states-postal-servicepostal-history-of-the-united-statesrear-wheel-drive-vehiclestrucksgrumman-vehiclespostal-vehiclesvehicles-introduced-in-1986vehicles-discontinued-in-1994