Deliveries of the KC-46A Pegasus aerial refueling tanker are expected to resume within days, following a months-long suspension due to the discovery of structural cracks. While the resumption marks progress, the troubled program continues to face delays in its key Remote Vision System (RVS) upgrade, pushing full operational capability back to 2027.
Structural cracks identified, most repaired
In February 2025, the US Air Force (USAF) halted deliveries after detecting cracks on two aircraft that had just rolled off the production line. Further inspections found similar issues on 21 of the 89 KC-46As already delivered.
The cracks were found on critical support structures, prompting Boeing and the USAF to jointly investigate potential causes and implement corrective actions.
Officials have now confirmed that the root of the issue has been addressed. All but three of these have since been repaired, clearing the way for new aircraft to be accepted once again, Darlene Costello, the USAF’s chief of acquisition, technology and logistics, said during a congressional hearing on May 7, 2025.
Remote Vision System 2.0 hits more delays
Even as deliveries resume, the more complex and long-standing challenge remains the Remote Vision System. Designed to give boom operators a precise, camera-based view during aerial refueling, RVS 2.0 was meant to correct image distortion and depth perception flaws found in the original system.
Despite multiple revisions and investments in new 4K sensors and displays, the system has fallen short of expectations. According to US Air Force Chief of Staff General David Allvin, the version currently in testing is “operating, it’s just not operating as we would expect”. Two of the aircraft’s five remaining critical deficiencies are tied to the RVS 2.0, and a fully operational version is not expected until the end of fiscal year 2027.
The USAF began installing RVS 2.0 hardware on the first aircraft in April 2025, with flight testing scheduled to start later this year. Officials are pushing Boeing to accelerate the timeline, in particular by resolving FAA certification delays.
Long repair times, availability concerns
The KC-46A also continues to suffer from long maintenance turnaround times, with parts shortages contributing to reduced aircraft availability. A recent Pentagon review highlighted the ongoing logistical and supply chain issues plaguing the program.
Given the slow progress and the age of the existing tanker fleet, the USAF may be forced to extend the service life of its KC-135 Stratotankers, some of which are over 60 years old. Senior commanders have indicated that, at the current recapitalization rate, these legacy aircraft could remain in service well into the 2050s.
The KC-46A’s development has been marred by recurring technical problems, from early production debris issues to fuel leaks, stiff refueling booms, and now vision system delays. These problems have already led Boeing to incur billions of dollars in losses, including a further $800 million charge in early 2025.
However, with the retirement of the KC-10 Extender and no viable alternative in the short term, the USAF has little choice but to persevere with the Pegasus, despite its uneven track record.
