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

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.