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An Investigation Found the Turret Gearbox on the British Army’s New £1,900,000,000 Challenger 3 Tank Is Not Strong Enough and Could Cause a 2 Year Delay

Britain’s Challenger 3 gets a new turret, a Rheinmetall 120mm L55A1 smoothbore, and a 66-ton weight, down from 75, but the turret gearbox is too weak, insiders warn of a two-year slip past 2027, the budget is now $2.4 billion, or $17 million a tank, and the Army is converting just 149. Kursk alone consumed 121 tanks.

Challenger 3 Tank
Challenger 3 Tank. Image Credit: British Government.

Summary and Key Points: Expert Isaac Seitz assesses Britain’s Challenger 3 main battle tank, a Challenger 2 rebuild with a new turret, Rheinmetall 120mm L55A1 smoothbore gun, modular and reactive armor, Perkins CV12-9A engine, hydrogas suspension, and a weight cut from 75 to 66 tons. The Telegraph reports a turret gearbox too weak to rotate it, risking a two-year slip from the 2027 initial operating capability; the budget rose from £1.3 billion to £1.9 billion, $17 million a tank, for 149.

The Challenger 3 Tank Challenge

The Challenger 3 is the UK’s next-generation main battle tank (MBT). While looking strong on paper, the program has faced real challenges over the years. The program aims to completely overhaul the current Challenger 2, which has received no major upgrades since 1998.

The tank retains the same basic hull and layout as the Challenger 2, but with an entirely new turret, improved suspension, and drastically improved firepower and situational awareness.

With these upgrades, the Challenger line is expected to remain in service until the 2040s.

The tank was originally slated to reach initial operational capability (IOC) by 2027; however, due to newly encountered technical problems, the program may be delayed.

Delays on the Horizon?

According to The Telegraph, the Challenger 3 program has encountered some technical difficulties, particularly with the turret’s new gearbox.

The gearbox, which is responsible for rotating the tank’s turret, is apparently not strong enough. 

Rheinmetall BAE Systems Land (RBSL), the consortium responsible for the project, is currently scrambling to fix the issue and has reportedly told some subcontractors to pause their work entirely.

Challenger 3 British Army Photo Handout

Challenger 3 British Army Photo Handout

Challenger 3 Tank British Army Photo

Challenger 3 Tank British Army Photo

The British Ministry of Defense (MoD) remains confident it will resolve the issue quickly, at no extra cost to the taxpayer, and that the tank is still set to be delivered to the British Army next year.

However, some insiders informed The Telegraph that the technical difficulties could delay the project by as much as two years.

This is not the first time that the program has encountered issues. Last year, UK Defense Procurement Minister Maria Eagle stated that the Challenger 3 had been impacted by “some delays” in the supply chain.

She did not specify what those supply issues were or whether the delays would affect the MoD’s goal of reaching initial operational capacity.

“Additional resources have been directed towards resolving these issues, and the next phase of trials will start in Quarter 2 2025. Progress will be monitored carefully, and any impact on the delivery of initial operating capability will be continually assessed,” Eagle said.

To reach IOC, the MoD needs to receive a full squadron of Challenger 3s, which is somewhere between 12 and 16 tanks. 

Assessing the Cost of the Challenger 3

Over the course of the program, the UK MoD has allocated more funds to the Challenger 3 program.

In 2021, the project was allocated an initial budget of “around £1.3 billion” ($1.7 billion).

In 2025, the government disclosed that the program’s Approved Budgetary Level had risen to £1.9 billion ($2.4 billion).

If the program spends its entire budget, the Challenger 3 could cost up to £12.8 million ($17 million) per tank.

For comparison, the U.S. Army pays about $10 to $15 million per tank for the M1 Abrams.

U.S. Soldiers assigned to 1st Battalion, 9th Cavalry Regiment, 2nd Armored Brigade Combat Team, 1st Cavalry Division fire an M1 Abrams main battle tank at an enemy target during Rotation 25-02 at the National Training Center, Fort Irwin, Calif., Nov. 07, 2024. Rotations at the National Training Center ensure Army Brigade Combat Teams remain versatile, responsive, and consistently available for current and future contingencies. (U.S. Army photo by Spc. Casey Auman, Operations Group, National Training Center).

U.S. Soldiers assigned to 1st Battalion, 9th Cavalry Regiment, 2nd Armored Brigade Combat Team, 1st Cavalry Division fire an M1 Abrams main battle tank at an enemy target during Rotation 25-02 at the National Training Center, Fort Irwin, Calif., Nov. 07, 2024. Rotations at the National Training Center ensure Army Brigade Combat Teams remain versatile, responsive, and consistently available for current and future contingencies. (U.S. Army photo by Spc. Casey Auman, Operations Group, National Training Center).

As for new tank procurements, the Challenger 3 isn’t doing too badly yet, but incremental budget increases are never a good sign.

The biggest drawback of the Challenger 3 program is less the tank’s design or the technical delays (yet). Those issues can get ironed out with time.

Rather, the biggest drawback is the small number of tanks the UK plans to field.

Under the current plan, the UK MoD will convert 149 tanks to the new Challenger 3 standard.

For a tank marketed as the UK’s prime deterrent against Putin, this low number of tanks reveals a miscalculation on the part of the MoD if they think it’s anywhere near enough for a full-scale confrontation (more likely, it’s because the UK lacks the funds for more).

For comparison, in Ukraine’s ill-fated Kursk incursion, both sides lost a combined total of 121 tanks, not counting the total number of armor used, and this was just one sector of the vast front line in Ukraine.

One could argue that the UK plans to fight its future wars with allied support, which is fair, but if London finds itself in a conflict on its own, the Brits are in for a shock.

Challenger 3

Challenger 3 Image Credit: BAE Systems.

What Does the Challenger 3 Bring to the Table?

On its own, the Challenger 3 is not a bad tank.

On paper, it seems like a good tank.

Fitted with a brand-new turret, featuring a new generation of advanced composite armor and modular external armor and explosive reactive armor for protection against all kinds of threats.

The tank also features the Rheinmetall 120mm L55A1 smoothbore gun, replacing the older rifled L30A1 gun.

A major goal of the program is to enhance the crew’s situational awareness through new state-of-the-art sensors and communication systems, most of which have not been made public yet.

For mobility, the Challenger 3 receives a Perkins CV12-9A V12 diesel engine and a new hydrogas suspension system.

Overall, the tank’s weight has been reduced to 66 tonnes compared to the 75 tonnes of a current Challenger 2 with armor packages.

British Challenger 2 Tank.

British Challenger 2 Tank. Image Credit: Creative Commons.

The tank is expected to have a better power-to-weight ratio compared to its predecessor. These changes are a welcome improvement on the Challenger 3.

They retain the original platform’s strengths while increasing its firepower, survivability, mobility, and situational awareness.

While some may argue the program isn’t enough to keep the tank relevant in the future, the Challenger 3 arguably has everything it needs to remain a potent force on the battlefield. 

About the Author: Isaac Seitz

Isaac Seitz, a Defense Columnist, graduated from Patrick Henry College’s Strategic Intelligence and National Security program. He has also studied Russian at Middlebury Language Schools and has worked as an intelligence Analyst in the private sector.

Written By

Isaac Seitz graduated from Patrick Henry College’s Strategic Intelligence and National Security program. He has also studied Russian at Middlebury Language Schools and has worked as an intelligence Analyst in the private sector.

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