The KC-135 fleet makes up most of the inventory of USAF air refueling tanker aircraft. Before 911, USAF predicted that it could fly the KC-135 out to the 2030-2040 years. Various post Cold War contingencies like Operation Northern Watch, Operation Southern Watch (the Iraq no-fly-zones of the day), and support of operations over the ex-Yugoslavia (including Allied Force) as well as other day to day duties, kept the aging air refueling fleet busy.
Ops tempo for these aircraft have picked up even more after 911. The KC-135 is a three-level maintenance aircraft. This means that it receives routine flight line maintenance and every few hundred hours it goes into “phase” and “issochronic” maintenance in a hanger at its home base. This involves various inspections and detailed fixes of the aircraft systems. Finally, every so many years or flying hours, it goes to the depot at Tinker Air Force Base, Oklahoma to get stripped down and refurbished.
With the increased ops tempo, the original plan of making this aircraft last to the year 2030-2040 is at risk. Each airframe now spends more time for each depot visit as new corrosion or other aircraft age discoveries show up.
The USAF thought it knew everything there was about three-level maintenance on the F-15 Eagle fighter jet. Then a manufacturing defect showed up two year ago and grounded a huge portion of the fleet after an in-flight catastrophic failure.
The KC-135 tanker fleet is just one surprise maintenance discovery and/or catastrophic failure away from suffering a long term grounding. All of the U.S. fighting forces depend on tanker gas for almost every operation. U.S. Air Power is the permission slip to make any U.S. war fighting operation happen. One bad KC-135 maintenance event means U.S. air power will be crippled.
Procurement of new air-refueling tankers has to be looked as an urgent priority. Or, some years from now people will stand around with a stupid look on their face with the whole KC-135 tanker force grounded due things we should have taken care of years ago.










