Boeing faces hurdles in delivering new Air Force One jets amid workforce challenges

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Boeing faces hurdles in delivering new Air Force One jets amid workforce challenges

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Boeing's Air Force One | Official Website

By Sky Industry News

Jun 30, 2025

Boeing's Air Force One program is facing ongoing challenges, particularly in hiring and retaining qualified mechanics. The Boeing 747 VC-25B program, which aims to replace the current presidential jets with modified 747-8 jumbos, has been delayed by design issues and modification rework.

Recently, Boeing appointed a former Northrop Grumman executive to lead the program. Despite proposing delivery of the new jets by 2027, there remains no definitive timeline for their readiness as workforce and other issues persist.

A report from the US Government Accountability Office highlighted that design issues, modification rework, and workforce challenges have hindered progress. Four schedule risks remain unresolved, including difficulties in recruiting qualified mechanics due to market conditions. Boeing has launched hiring campaigns in San Antonio, where approximately 3,000 of its Texas-based employees work at Port San Antonio on modifications for the new Air Force One.

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Design issues related to decompression and environmental control systems are also affecting progress. Boeing is conducting a study to address these concerns and expects to make necessary design changes. Wiring delays have led to further modification rework.

While Boeing continues with test plans, many remain incomplete pending certification plans and aircraft design finalization. The proposed schedule does not account for time between development testing and operational testing phases.

Initially expected in 2024, delivery of the new jets has been delayed several years due to various issues including the COVID-19 pandemic. A revised schedule suggests further delays until December 2029 unless requirements are relaxed by the Air Force.

The cost of the program has risen from an initial estimate of $3.9 billion to up to $5.6 billion due to ongoing design and modification challenges, unplanned maintenance, and repairs for stress corrosion cracks discovered in 2019.

Steve Sullivan from Northrop Grumman now leads the program following Gregg Coffey's reassignment within Boeing. As President Trump awaits his new aircraft, he has accepted a gift of a Boeing 747 from Qatar as an interim solution.