CORRECTION

A front-page article Thursday incorrectly reported the number of V-22 Ospreys deployed to Iraq. The correct number is 10.

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When the Marines shipped their V-22 Osprey aircraft to Iraq last year, they had to leave behind the assault vehicles and mobile mortar system that fit inside the planes.

The Marines' new mortar system can't safely carry its ammunition.

That conclusion, from a government audit, is the most recent bad news for the Marines' attempt to ferry firepower inside the Osprey. The Defense Department inspector general is investigating the program, which is two years behind schedule and $15 million over budget.

The system consists of a jeeplike vehicle called the Growler that pulls trailers carrying mortars and ammunition.

The Growler, made in Robbins, N.C., costs $127,000 each and cannot safely pull its ammunition trailer, according to interviews and the report from the Government Accountability Office. The trailer has a tendency to bounce or tip over, which could crush a Marine riding in the back of the Growler. A Growler, not pulling a trailer, was reported to have tipped over last summer when it swerved to avoid a turtle in the road.

The Marines won't discuss the program, known as the Expeditionary Fire Support System, because of the Defense Department's investigation.

The problems were predictable, said Philip Coyle, who directed the Pentagon's weapons testing from 1994 to 2001. The Marines decided to start production before testing the vehicle and mortars, Coyle said.

"It is a sign of rushing to failure," he said.

The Osprey is a rotorcraft that takes off and lands like a helicopter and tilts its huge rotors forward to fly like an airplane. The aircraft, which costs $119 million each, has suffered cost overruns, a string of crashes that left 30 dead, and repeated watering down of specifications during its two decades of development. The Pentagon has declared that most of the Osprey's problems have been fixed, and the first squadron of 12 Ospreys went to Iraq in October.

In 1999, the Marines decided the Osprey program needed assault vehicles to carry men and mortars on the battlefield. Some Growlers will pull the mortar systems on trailers. Others will be outfitted with a machine gun. The Ospreys are designed to take off from ships and go inland faster than helicopters. Once they land, the Growlers would provide assault firepower or machine gun cover for Marines on foot.

In soliciting bids in 2004, the Marines announced they had "an aggressive schedule."

In November 2004, the Marines awarded the contract to General Dynamics, which produced the mortar system. The defense giant uses a company in Robbins, Carolina Growler, to build a modified dune buggy with a design that recalls Vietnam-era jeeps.

Gov. Mike Easley awarded Carolina Growler a $25,000 grant, and U.S. Rep. Howard Coble helped get a $300,000 grant and a $112,000 loan for the company from the U.S. Department of Agriculture.

Contract complaint

The contract award was controversial because the founder of Carolina Growler, Terry Crews, is a retired Marine colonel with strong connections. The Defense Department received an anonymous complaint claiming that Crews was a close friend of Brig. Gen. William Catto, who headed the agency that awarded the contract, Marine Corps Systems Command in Quantico, Va.

The complainant, who identified himself as a career procurement professional, said Catto steered the contract to Carolina Growler and General Dynamics.

After demonstrations from three companies, the selection committee recommended the contract go to a team of United Defense, which supplied the mortar, and Rae-Beck Automotive of Michigan, which built a new vehicle from scratch. According to the complaint, the United Defense bid was technically superior and cost less, while the Growler flunked crucial tests and was coupled to a much more expensive mortar system.

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