The U.S. Air Force has again stopped deliveries of new KC-46A Pegasus tankers after finding trash in the new airplanes' fuel tanks. It’s the latest in a series of incidents in which garbage has been found inside the new made tankers, potentially causing serious safety issues. According to Air Force Times, the debris was found in the fuel tanks of one of two KC-46A tankers being delivered to Seymour Johnson Air Force Base. The issue first cropped up in 2019, when Air Force inspectors found numerous KC-46A tankers with trash inadvertently sealed into the airplanes. The head of the Air Force’s acquisition program, Will Roper, described the situation as “severe.” Air Force pilots refused to fly the airplanes, citing the potential dangers.
The debris has included “aluminum shavings,” hand tools, loose nuts, “rubbish,” and other items that inspectors worried could damage electrical wiring, leading to system failures in flight. The problem is mirrored on Boeing’s civilian aircraft assembly lines, where tools, rags, titanium shavings, metal nuts, tubes of sealant, a string of lights, and even a ladder were found left behind in 737 MAX aircraft.
The KC-46A has suffered from other problems, including issues with its fuel probe and the remote vision system that allows the crew to refuel aircraft. The KC-46A has racked up $4.6 billion in cost overruns over the life of the program. Boeing will have to swallow those overruns per the terms of the contract.