The US Air Force (USAF) has upgraded an existing deficiency of the Boeing KC-46A Pegasus aerial refueling tanker to the most serious category after identifying excessive fuel system leaks in 16 aircraft.
The leaks were first discovered in July 2019 after an air refueling test, according to the USAF. The service and Boeing are working together to determine the root cause and to implement corrective actions.
The KC-46A Test 004-002 was the initial F-16 contact and fuel pass flight that was conducted on January 24, 2016. (US Air Force)
Boeing spokesman Larry Chambers said on 31 March that the KC-46A fuel system is equipped with redundant protection for fuel containment. In some cases with this issue, Chambers said aircraft maintenance crews are finding fuel between the primary and secondary fuel protection barriers within the system.
Boeing is implementing assembly and installation improvements, and has repaired several affected aircraft, and will continue to implement repairs as needed. The company has fixed seven of the 16 affected aircraft.
Each affected KC-46A is being sent to a “rapid response” Boeing facility in San Antonio, Texas, that is equipped to handle aircraft maintenance and other work. The fuel system improvements made there are also being incorporated into the assembly of the company’s new tanker aircraft.
Boeing expects inspection and repairs of the fuel system to take roughly 10 days for each aircraft. Chambers said the platforms will fly to San Antonio on a non-interference basis according to the USAF schedule. Boeing, he said, is making it a priority to complete these inspections and repairs as soon as possible.
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