The U.S. Air Force has suspended the delivery of KC-46A Pegasus tankers following the discovery of structural cracks.
According to Newsweek, the recent findings prompted an immediate inspection of all 89 aircraft in the fleet.
The KC-46A Pegasus, a military aerial refueling aircraft, has faced various challenges since Boeing was awarded the contract in 2011 to replace the aging KC-135 Stratotankers. The first delivery, initially expected earlier, was completed in January 2019 after overcoming multiple hurdles including issues with its refueling systems and vision technologies.
The cracks, which were found on two new aircraft, have raised concerns about the structural integrity of the fleet. Boeing and the Air Force are now working together to determine the severity of the issue and its implications on the aircraft currently in production as well as those already in service.
Continued Setbacks in the Pegasus Tanker Program
Previously, the program grappled with technical difficulties involving the refueling boom and the Remote Vision System (RVS), critical components necessary for its operation. These challenges contributed to prolonged delays and escalated costs, pushing the program's expenses higher.
According to Boeing, these new structural issues seem to affect the primary or secondary structures of the aircraft but not flight surfaces like the wings or hinges. The comprehensive inspections will focus on identifying similar faults to ensure the fleet's safety and reliability.
"We are working closely with the customer to assess a potential issue on KC-46A aircraft and to mitigate any potential impact to the fleet and in-production airplanes," a Boeing spokesperson stated, highlighting their commitment to swiftly resolve this issue.
Technical Delays and Financial Strain
The implications of these recurring issues are significant, not only for the Air Force's operational capabilities but also for Boeing's financial health. The aerospace giant has already incurred an estimated $800 million in losses due to the Pegasus program's ongoing problems. Such setbacks have tarnished the company's reputation and strained its financials.
In the latest evaluations, the aircraft has failed to meet several key performance metrics. According to the January 2025 report from the Director of Operational Test and Evaluation (DOTE), the KC-46A's operational availability and mission capable rate fell below the required thresholds of 80% and 90%, respectively.
The operational challenges have been further compounded by previously identified defects in the remote vision system and other key technologies, leading the U.S. Government Accountability Office in January 2022 to note that full operational capabilities were delayed.
Boeing's Future Plans to Address Issues
In response to the series of setbacks, Boeing has outlined plans to overhaul the KC-46A's systems. These improvements include both hardware adjustments and software updates, aiming to refine the refueling boom and introduce a revised version of the RVS.
Such efforts are critical not only for fulfilling the Air Force's immediate operational needs but also for restoring confidence in the program, which has been marred by technical disruptions and escalating costs.
The ongoing scrutiny of the KC-46A Pegasus reflects the complexity and the high stakes involved in modern military aviation programs. As Boeing and the U.S. Air Force work closely to resolve these issues, the outcome will significantly impact future aerial refueling capabilities and defense readiness.
While the temporary halt in deliveries presents immediate challenges, it also underscores the rigorous standards to which military aircraft are held, ensuring that performance and safety are not compromised. The resolution of these issues will be crucial for the program's future success and the strategic capabilities of the U.S. Air Force.
