KC-135 brakes changing to carbon Published Sept. 17, 2003 By Gary Boyle Ogden Air Logistics Center Public Affairs HILL AIR FORCE BASE, Utah (AFPN) -- Air Force KC-135 Stratotanker brake systems will go from metal to lighter, longer-lasting carbon now that service officials approved an initiative proposed here, that will save millions in tax payer dollars.Dubbed the “largest improved item replacement program in Air Force history,” the new commercial-rated brake system will not only last longer, but require less frequent maintenance, according to Capt. Adam Curtis. He is the project program manager who estimates that approximately 99 percent of the savings will come from parts.The last Stratotanker was delivered in 1965, and the 581 aircraft in service are beginning to show their age, Curtis said. The aircraft have also undergone modifications and retrofitting, expanding their fuel storage area and gross-weight liftoff abilities. As a result, the current steel brakes are good for 100 sorties, making brake replacement an annual event."The objective is to improve reliability and maintainability," Curtis said. "The carbon-brake systems will last for 1,000 sorties, which is about 10 years of operation."Additionally, the new brake system eliminates axle damage and is about 500 pounds lighter, meaning the tanker can carry more fuel and maintain stopping performance, he said.The new brakes will be retrofitted at Tinker Air Force Base, Okla., during program depot maintenance. All fleet aircraft will use the carbon brakes by October 2009, Curtis said.Each system costs $13,150, which is $2,000 less than the steel brakes, Curtis said. They will take 20 to 25 hours to install, and each Stratotanker has eight brake systems. Crews will replace 4,648 systems.The workforce maintaining the KC-135 will experience a drop-off in workload once the carbon brakes are installed, he said. The steel brakes require more than 54,700 of direct labor hours per year.Officials estimate the carbon-brake retrofit will cut labor hours to 5,472, according to Curtis. This will allow the freed-up workforce to be moved to other mission-essential duties.The KC-135 is scheduled to remain in the fleet until 2040.