KC-135 Upgrades

Abstract

The KC-135 is the US Air Force's aerial refueling workhorse. In FY 2023, USAF KC-135s offloaded 64,946,367 gallons of fuel and refueled 38,360 aircraft in support of global operations. The KC-135 provides air refueling through either the refueling boom or drogue. As a cargo aircraft, the C/KC-135 can carry six (6) standard 463-L pallets. KC-135 modernization funding is vital to ensure the KC-135 fleet can support global aerial refueling operations to 2050 and beyond. RDT&E efforts include but are not limited to Mobile User Objective System, COMM2 Crypto & Data, High Frequency Modernization, Center Console Refresh, and Winglets. Mobile User Objective System (MUOS): Integration and test for MUOS-capable radios on Block 45 aircraft in the COMM 3 position with Beyond Line-of-Sight (BLOS) Integrated Waveform (IW) and LOS SATURN capability with HAVE QUICK II backward compatibility. The KC-135 fleet must comply with the National Security Agency (NSA) mandate or will lose secure communications, which significantly degrades its ability to support worldwide operations. The ARC-210 Gen 3 radios have Diminishing Manufacturing Sources and Material Shortages (DMSMS) and will become obsolete on the CEASEKEY date. Requirement: AMC's 10-050 Crypto, 15-046 MUOS, 16-053 SATURN, and 17-039 IW. This modification is part to the USAF RCMP for crypto modernization as directed by CSAF in Nov 2022 and DoD CIO in 2016. Center Console Refresh (CCR) replaces the Flight Display System (FDS) and Fuel System (FS) that is facing parts obsolescence issues and will render the aircraft non mission capable. The Integrated Fuel Management Panel (IFMP) and Fuel Management Advisory Computer (FMAC) are no longer procurable with limited repair capability. The Multi-Function Displays (MFD) are out of production with a limited cache of Liquid Crystal Display (LCD) glass. The A11 card within the Control Display Unit (CDU) is obsolete and no repair capability exists at this time. Current organizational maintenance efforts to cannibalize and repair have negated the impact so far. CCR fleet impacts will be experienced with the with the IFMP as early as 4QFY23 and with the CDU 2QFY25 to the effect of up to 30 aircraft per quarter. Requirement: AMC's 22-009 High Frequency (HF) Modernization: Integration and test to replace legacy HF radio with a modernized HF radio on KC-135 aircraft. A modernized HF communications capability is necessary to enable future sustainability and growth to operate in satellite communications (SATCOM)-denied environment while maintaining global, secure voice and data between Mobility Air Forces' aircraft and command and control (C2) agencies to exchange classified information. Requirement: AMC's 18-100 Modernized HF. This modification is part to the USAF RCMP for crypto modernization as directed by CSAF in Nov 2022 and DoD CIO in 2016. COMM2 Crypto and Data: Integration and test for ARC-210 Gen 3 radio replacement in the COMM 2 position with secure voice and SATURN capability with HAVE QUICK II backward compatibility, and a replacement solution for the Very High Frequency (VHF) Data Link (VDL)-2000. The KC-135 fleet must comply with the NSA mandate or will lose secure communications which significantly degrades its ability to support worldwide operations. The ARC-210 Gen 3 radios have DMSMS and become obsolete on the CEASEKEY date. VDL replacement is required for civil airspace compliance. Requirement: AMC's 10-050 Crypto, 16-053 SATURN, 22-033 VDL Solution. This modification is part to the USAF RCMP for crypto modernization as directed by CSAF in Nov 2022 and DoD CIO in 2016. Winglets: Research and development of winglets for KC-135 aircraft to increase operational energy. This effort continues Air Force Research Laboratory's initial prototyping. MAF Connectivity: Capabilities using the KC-135 to develop MAF Connectivity path forward as the tanker needs to be able to connect to the Joint fight to close kill chains and logistics chains. Possible capabilities include, but are not limited to, intelligent gateways, antennas, radios, software updates, crew displays, and multiple aperture array housings. This program element may include necessary civilian pay expenses required to manage, execute, and deliver weapon system capability. The use of such programs funds would be in addition to the civilian pay expenses budgeted in program element 0605827F, 0605828F, 0605829F, 0605831F, 0605832F, 0605833F, 0605898F, and 0606398F. In FY 2023, $0.360M was expended for civilian pay expenses in this program element, and in FY 2024, $1.910M is forecast for civilian pay expenses in this program element. This program is in Budget Activity 7, Operational System Development because this budget activity includes development efforts to upgrade systems that have been fielded or have received approval for full rate production and anticipate production funding in the current or subsequent fiscal year.

Document Details

• Document Type: Project
• Publication Date: Oct 01, 2025
• Source ID: 675261_0401218F_7_3600_PB_2025

Tags

Readers

• Aerospace logistics and air mobility.
• Civilian Systems Systems Program Capability Development and Upgrade Support Activity Expense and Pay Management.
• Tactical Satellite Communications Systems Engineering.

Technology Areas

• Fully Networked C3
• Fully Networked C3 - Command and Control
• Space