The collaboration between Boeing and the US Air Force on the KC-46A Pegasus tanker program is under renewed pressure following the discovery of cracks on two of the aircraft scheduled for delivery. This latest development has raised concerns about the reliability of the already widely criticized tanker system and forced the parties involved to temporarily suspend deliveries. In this context, the entire fleet of KC-46A Pegasus aircraft already in service has also been inspected for potential defects.
On February 28, 2025, it was reported that two of the four KC-46A Pegasus aircraft scheduled for delivery to a military delivery center had been found to have cracks in the primary and secondary structures. These cracks were discovered during final inspections prior to delivery of the aircraft, prompting the need for immediate inspection and investigation by Boeing and the U.S. Air Force. As a result, deliveries of these two aircraft were temporarily halted to determine the causes of the cracks and prevent potential impacts to other aircraft.
Boeing confirmed the reports and said in a statement that it was working closely with the customer to assess the situation and mitigate the impact on the fleet and aircraft still in production. The US Air Force also announced that it would review its existing fleet of 89 KC-46A Pegasus aircraft for any defects, further increasing concerns about the long-term reliability of the system.
Challenges in the development of the KC-46A Pegasus
The KC-46A Pegasus is an essential element of the US Air Force's strategic air mobility. The aircraft was designed to enable aerial refueling, cargo transport and medical evacuation. However, the program has struggled with numerous technical problems and quality defects since its launch in 2016. Even before the first delivery in January 2019, there were already significant difficulties, particularly with the Remote Vision System (RVS), developed by Rockwell Collins, which is supposed to be able to control the refueling booms. These problems affected the crew's ability to safely operate the refueling boom, leading to repeated rework and delays.
Over time, other defects emerged, such as faulty quick-release fasteners in the cargo area, fuel leaks, and problems with the refueling boom itself. These defects were a recurring theme and even led to two stop-shipment measures in 2019 after inspections found foreign objects such as tools and misplaced parts on the aircraft. These defects raised concerns about Boeing's manufacturing discipline, further undermining confidence in the aircraft manufacturer's production quality.
Financial impact and rising costs for Boeing
The repeated technical difficulties and delayed deliveries of the KC-46A Pegasus have also placed a significant financial burden on Boeing. According to Boeing's fourth quarter 2024 results, released in January 2025, the company had to add an additional $1,7 billion in defense costs to its balance sheet, with $800 million allocated specifically to the KC-46 program. These financial burdens resulted from the need to repeatedly make improvements to the aircraft, which delayed production and delivery.
There was also another incident in July 2024, when the US Air Force filed a so-called "Category 1" defect report regarding the fuel pump system. This could have potentially caused damage to the engine air system, which is important for cabin ventilation and cooling of the systems. Although a short-term solution was implemented, this incident underscored the ongoing technical fragility of the Pegasus tanker, further increasing concerns about the long-term operational viability of the aircraft.
The strategic importance of the KC-46A for the US Air Force
Despite these ongoing difficulties, the U.S. Air Force has little choice but to rely on the KC-46A Pegasus. The older KC-10 Extender is due to be retired in 2024 and the KC-135 Stratotanker fleet is being phased out of active service. These developments force the U.S. Air Force to rely on the KC-46A, even though the aircraft still struggles with significant technical challenges. The need to maintain the tanker fleet requires that the Pegasus tankers remain in service despite their shortcomings.
But the KC-46A Pegasus' problems raise questions about how Boeing and the U.S. Air Force can address these long-term and costly deficiencies without jeopardizing the tanker fleet's operational capabilities and, in turn, the U.S. military's aerial refueling capabilities. Further delays and financial burdens could further strain the already strained relationship between the manufacturer and the military.
Outlook on the future of the KC-46A program
Boeing and the U.S. Air Force now face the challenge of correcting the KC-46A Pegasus' technical deficiencies and restoring confidence in the aircraft. The company has already made significant financial investments to improve the quality of the aircraft and is expected to continue investing in correcting the deficiencies. Nevertheless, it remains to be seen whether Boeing will be able to get the KC-46A program fully on track and resolve all technical issues before the aircraft can reach its full potential in U.S. Air Force service.
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