Damage occurred to a KC-46 refueling system during the process of refueling F-22 fighter jets.
On July 8, 2025, a U.S. Air Force KC-46 Pegasus aerial refueling tanker experienced a boom detachment while refueling F-22 Raptors off the U.S. East Coast. The incident, which occurred during a training mission, prompted the aircraft to declare an in-flight emergency and divert to Seymour Johnson Air Force Base in North Carolina, where it landed safely without any injuries or damage to the F-22s.
Currently, a safety investigation is underway to determine the nature and causes of the boom detachment. This incident marks the second known case of a boom separation involving the KC-46, raising concerns about the structural resilience of the boom system. No further details have been released regarding the specific findings of the investigation at this time.
The KC-46, based on the commercial 767 airframe, has had issues, particularly with its refueling system. A long-standing problem with the KC-46 is a "stiff boom," which prevents the aircraft from refueling the A-10 Thunderbolt II. Contractors and the Air Force are working on a redesigned actuator as a fix for this issue.
The aircraft involved in the incident is a six-year-old KC-46, serial number 17-46033. Prior to the incident, the KC-46 had flown two missions on July 7 without any reported difficulties. An image shows the tanker at Seymour Johnson with part of its boom missing. The crew reported that the boom "detached" during the incident.
Officials will inspect the aircraft to determine the presence and severity of any potential damage. The KC-46A Pegasus from McConnell Air Force Base, Kansas, had been refueling the F-22 Raptors at Langley Air Force Base, Virginia, before the incident. The F-22 Raptor, which was being refueled, returned and landed safely at Langley Air Force Base after the KC-46 declared an in-flight emergency and diverted to Seymour Johnson.
It is important to note that the KC-46A is not meeting many of its suitability metrics, according to the Pentagon's Office of the Director of Operational Test and Evaluation. Boeing resumed deliveries of the KC-6 in May after the Air Force halted acceptance for months due to cracks in the wings. The Remote Vision System 2.0, used by boom operators to guide the boom, has been delayed until summer 2027.
Air Force officials are still working to verify details surrounding the mishap and the extent of the damage to the aircraft. The KC-46A Pegasus from McConnell Air Force Base has landed safely at Seymour Johnson Air Force Base, North Carolina, and will remain there for the time being.
- The safety investigation into the boom detachment incident on the KC-46 Pegasus, which occurred on July 8th, 2025, is currently underway at the Pentagon.
- The KC-46 involved in the incident, serial number 17-46033, is a six-year-old aircraft that had flown two missions the day prior without any reported difficulties.
- The aerospace industry and the Air Force are working on a redesigned actuator as a solution for the "stiff boom" issue with the KC-46, a problem that has prevented it from refueling the A-10 Thunderbolt II.
- The Space Force and General-news media are closely monitoring the latest developments, as the KC-46 incident marks the second known case of a boom separation, raising concerns about the structural resilience of the boom system.
- The finance industry is closely watching the handling of the KC-46's issues, given the cost overruns and delays in the project, with the Remote Vision System 2.0 delayed until summer 2027 and Boeing halting deliveries for months due to cracks in the wings.
