Since December 2003, the Marine Corps began fielding the Interceptor system to Marines deployed in support of Operations Iraqi and Enduring Freedom. Initially, the Corps outfitted about 26,000 personnel for OIF with body armor, which constitutes 52,000 SAPI plates. The MEF had about 17,000 SAPI plates from the previous deployment to Iraq, when it started preparing for the 2004 deployment. During the testing and purchasing process, the Marine Corps started to receive test data on some of the OTVs that were lower than what was specified in the requirement for the purchase description. This was clearly a concern that the Marine Corps had to address. The Corps looked at the data to see how far off they were from the acceptable levels of ballistic performance. It was easy to identify the fact that, despite the vest not being at full ballistic capability as outlined in the specification, they were still dramatically better than the alternative. The alternative was to send Marines into theater wearing an old flak system. It was never a doubt that all of the vests were clearly better than the PASGT system.

The OTVs that received lower ballistic performance ratings were still stopping 9 mm rounds during testing. The PASGT flak could not hold a SAPI plate and can not stop a round, so the choice was clear to sign the waivers for specific vests that showed lower-than-optimal performance on ballistics. During rapid fielding and equipping of forces for OIF II eleven (11) lots of otvs totalling 5277 vests were fielded with waivers that accommodated lower than contracted test results from a specific testing facility. Prior to approving waivers additional test data was collected on the lots in question. Ballistic protection performance of the lots was confirmed and they were subsequently fielded.

A Marine Corps Times article by Christian Lowe published on 09 May 2005 regarding the Outer Tactical Vest cast doubt on whether or not the OTV can stop a 9 mm round fired from a standard pistol such as the M-9 Berretta. The United States Marine Corps maintains that the OTV system is capable of defeating the 9 mm and other ballistic threats, in addition to providing protection from shrapnel and fragmentation.

The lots in question were urgently needed and fielded when Marines were ordered back into Iraq in spring and fall of 2004. The OTVs in every instance are a significant improvement in protection from the outdated Personnel Armor System for Ground Troops flak jacket they replaced. The decision to waive these lots was made in order to provide the best available individual protection equipment as Marines were rotating back into harm's way.

Because the Corps knew this article was forthcoming and could potentially sow seeds of doubt in the minds of Marines in active combat, the Corps concluded the only way to rapidly remove these doubts was to recall the lots in question. On 04 May 2005 the USMC Infantry Combat Equipment Program Management Office (PM ICE) of Marine Corps Systems Command recalled eleven (11) lots of OTVs totaling 5277 vests that were fielded during 2004 in order to ensure Marines were equipped with the optimal level of personal protection gear. However, the Corps maintained these vests were effective at meeting the threat posed by 9 mm pistol rounds. Present combat operations preclude retesting at this time to prove to Marines these vests are effective.

Of the approximately 19,000 vests the Marine Corps Times addresses, 5,277 vests were subject to recall. Additionally, of the then remaining 14, 000 vests questioned by the article, 10,000 vests were from lots that had never been accepted or fielded by the Marine Corps. In turn, of the remaining 4,000 vests, approximately 3,000 vests passed all quality and testing standards without requiring a waiver. The remaining 992 vests (two lots) also passed all quality and testing standards but were held for release by the Natick contracting officer because they were in the same production run as the recalled lots. Consequently, in order to get these 992 vests (two lots) released they had to be fielded with a perfunctory waiver to expedite their delivery to the Operating Forces.

Operation Iraqi Freedom casualty data gathered from the Office of the Armed Forces Medical Examiner and the Navy/Marine Corps Combat Trauma Registry proves that the OTV, a part of the Interceptor Body Armor System, is highly effective in reducing the number of lethal and non-lethal wounds to the chest and abdomen. This system is the most revolutionary personal protection system fielded to warriors in the past several decades. By early 2005 the Marine Corps had fielded more than 181,000 OTVs to Marines in the fleet. The recalled 5,277 OTVs in question represent less than three percent of the total number fielded.

Following the Corps' recall of more than 10,000 protective vests in November 2005, Marine Corps Systems Command officials defended the decision to initially field them to leathernecks in combat. Headquarters Marine Corps ordered 10,342 Outer Tactical Vests pulled from the operating forces after media reports indicated some samples tested by the manufacturer and by the Army's Aberdeen Proving Ground in Maryland failed to fully comply with ballistics standards.

Retired Lt. Col. Dan Fitzgerald, program manager for infantry combat equipment at Systems Command, said fielding the recalled vests, designed to stop fragmentation and 9 mm rounds, never presented a safety concern to deployed Marines or sailors. "The recall by no means indicates that the (Outer Tactical Vest) itself has any ballistic problems," Fitzgerald said. "At no time has the ballistic capability . on that vest been below operational capabilities requirements doctrine. Those vests were recalled for contractual purposes only, not for ballistic impact. It still stopped 9 millimeter and fragmentation as intended. We knew at the time that our choice was to either give the Marine an older vest that would not stop any ballistic shot and have less fragmentation (protection), or give them this system." Fitzgerald said the recall is entirely for the peace of mind of troops in theater in the wake of critical news reports, and, with 198,000 OTVs in the Marine Corps' inventory, will have zero impact on ongoing combat operations.

In January 2006 DefenseWatch / Soldiers for the Truth reported that a recent United States Marine Corps forensic study concluded that the Interceptor OTV body armor system was inadequate, noting that "as many as 42% of the Marine casualties who died from isolated torso injuries could have been prevented with improved protection in the areas surrounding the plated areas of the vest. Nearly 23% might have benefited from protection along the mid-axillary line of the lateral chest. Another 15% died from impacts through the unprotected shoulder and upper arm ...".

By late 2005 Marine Corps Systems Command was fielding both the Enhanced SAPI plate, with a greater degree of ballistic protection, and a new Interceptor system with additional SAPI plates to protect the sides of the torso from small arms fire. Four levels of add-on armor are now available for the Interceptor that offer the same degree of ballistic protection as the OTV for extremities, including the neck, shoulders, arms, groin and legs. The new armor can be configured for specific mission requirements and covers up to 75 percent of the body with four levels of add-on armor with ballistic protection for extremities, including the neck, shoulders, arms, groin and legs.