The U.S. Air Force continues to grapple with chronic issues with its next-generation refueling aircraft, the KC-46 Pegasus. Delays to the aircraft’s critical Remote Vision System (RVS) are of particular concern to the Air Force. According to recent statements, the revamped system, dubbed RVS 2.0, is not expected to be operational until the summer of 2027. This puts Boeing’s program more than three years behind schedule.
The delay, confirmed by an Air Force spokesman in an email statement Wednesday, means the current projection for fielding RVS 2.0 has been extended by about two more years. SözcüBoeing did not provide any details on what caused this latest schedule shift, and questions were directed to the Air Force.
Sözcü“The Air Force and Boeing are actively exploring various opportunities to prevent or mitigate disruptions to the program,” the Air Force said in a statement regarding the delays. However, this statement fell short of addressing current concerns, given how deep and complex the problem is.
KC-46's Revolutionary Vision System Turns Into a Nightmare
In older-generation refueling tankers, the KC-10 Extender and KC-135 Stratotanker, boom operators had a direct view through a window in the rear of the aircraft as they directed the refueling boom toward the receiver aircraft. In particular, boom operators in the KC-135 had to lie on their stomachs to do this.
From the moment it was first designed, the KC-46 Pegasus promised to revolutionize this difficult and uncomfortable way of working. Boom operators in the Pegasus would sit at special stations at the front of the tanker and use a system of advanced cameras, sensors and high-resolution displays to precisely direct the refueling boom.
However, the original KC-46 equipment, the Collins-built remote viewing system (RVS), was plagued with a series of unsolvable problems from the start. The faulty system could not respond quickly enough to changing sunlight and shadows, making it difficult for boom operators to accurately detect the location of the receiver aircraft. Worse, the system sometimes produced a distorted and misleading image that the Air Force feared could lead to receiver aircraft being hit by the refueling boom and suffering serious damage.
RVS 2.0 Hope Hits Supply Chain and Certification Stumbling Block
To address these critical issues, Boeing has developed a more advanced backup system for boom operators: RVS 2.0. The new system uses a range of state-of-the-art sensors, advanced displays and 3K ultra-high-definition cameras to provide boom operators with a high-resolution, 4-D, full-color image.
RVS 2.0 was initially scheduled to enter service in March 2024. However, this date had to be postponed several times due to unexpected issues in the global supply chain and unforeseen delays in the Federal Aviation Administration (FAA) airworthiness certification process.
Speaking at a hearing of the House Armed Services Subcommittee on Wednesday, Darlene Costello, the Air Force’s Deputy Chief of Staff for Acquisition, Technology and Logistics, made clear that certification issues have contributed significantly to recent delays in RVS 2.0.
Costello predicted that RVS 2.0 would likely enter service toward the end of fiscal 2027, around September 2027. But Costello added that the Air Force has pushed Boeing to speed up that process even further, in part by addressing delays in the FAA certification process.
“There are some assumptions that we’re not sure are fully in line with [the fiscal 2027 deadline], and we’ll be actively exploring ways to bring that date forward,” Costello said, suggesting the Air Force will continue to pressure Boeing to address this critical issue.
Costello also revealed that the Air Force has a fully functional prototype of the RVS 2.0 in its own labs, and that the service began installing the new system on its first KC-46 aircraft in April. Costello said that full-scale testing of that particular aircraft will begin later this year.
Costello, who said he has regular weekly meetings with Boeing officials about the Pegasus program and the problematic vision system, said the company and its subcontractors are determined to get Pegasus into the field eventually and at full capacity before the summer of 2027.
“The KC-46 is a great tanker, and once RVS 2.0 is fully and seamlessly in service, there will be nothing else that can compare,” Costello said. That bold statement shows the Air Force’s belief in the KC-46’s long-term potential, but it doesn’t hide its frustration with the current delays.
Critical Warnings from Air Force Commander
Air Force Chief of Staff Gen. David Allvin told lawmakers Tuesday that the KC-46 currently has five different Category 1 deficiencies that need to be addressed, two of which stem directly from the remote vision system.
Gen. Allvin predicted that RVS 2.0 could still require up to 18 months of development and testing before it becomes fully operational.
Speaking to the House Appropriations Committee, Gen. Allvin said of the current KC-46 fleet, “It’s working, but it’s not working exactly as we expected.” This honest and clear statement, It clearly shows that the performance expected by the Air Force from the new generation tanker has not yet been achieved.
Gen. Allvin also noted that the KC-46’s rigid refueling boom is an ongoing issue. He said the tanker still cannot safely refuel the Air Force’s A-10 Warthog, which plays a critical role in close air support missions, because of the boom rigidity issue, and that the KC-7’s refueling compatibility with the E-46 Wedgetail, the next-generation early warning aircraft the service plans to add to its fleet, has not yet been tested.
Gen. Allvin also revealed that a week ago, he and Air Mobility Command chief Gen. Jon Lamontagne met with Boeing Defense, Space and Security president Steve Parker to discuss key issues in the KC-46 program “line by line.”
General Allvin made an assessment of the current situation as, “It is possible, but certainly not at the best level,” and emphasized that the Air Force expects faster and more effective solutions from Boeing.
Cracks in Wing Structure Halt Deliveries
Costello also revealed that the Air Force conducted a rigorous inspection of all 89 KC-46 aircraft after unexpected cracks were discovered in the wing support structure of new tankers awaiting delivery into service. This significant discovery led the Air Force to temporarily halt deliveries of new tankers in February.
Similar wing cracks have been detected on 89 of the 21 tankers in the Air Force fleet, and all but three of those cracks have now been permanently repaired, Costello said.
But in welcome news, Costello announced that deliveries of newly built KC-46 tankers will resume next week. While that shows progress despite the program setbacks, the long delay in RVS 2.0 leaves it unclear when the Air Force will fully deploy its next-generation refueling capabilities.
