F-16 Fighting Falcon News

September 19, 2007 (by Staff reports) - Earlier this year, block 52 F-16C Falcons assigned at various Air Force bases started experiencing throttle binding problems while in flight.
In fact, an F-16 assigned to the 16th Weapons Squadron from the U.S. Air Force Weapons School experienced one of those incidences, forcing the pilot to eject over the Tonopah Test Range. While the pilot survived, the aircraft was a total loss.

Aug. 24, following an in-depth analysis of the incidents, Headquarters Air Combat Command directed units to ground specific aircraft that had undergone a previous modification. Furthermore, ACC directed the 57th Wing to change the throttle cables before the aircraft could be flown again. This caused significant turbulence within the Fighter Weapons School training and F-16 Aggressor programs since 12 of the total 19 aircraft affected belonged to the 57th Wing. Eleven grounded aircraft were assigned to the Tomahawk Aircraft Maintenance Unit and the other assigned to the Viper Aircraft Maintenance Unit. Until the throttle cables could be located, ordered, delivered and changed, one of the Wing's crucial missions--training the best fighter pilots in the world--was on hold.

The 57th Maintenance Group pressed ACC to deliver as many throttle cables as possible to the wing so they could complete the cable changes and return the aircraft back to service.

Senior Master Sgt. Charles Stuart, Tomahawk Aircraft Maintenance Unit lead production superintendent, stated, "It was the right thing to do, considering the Pratt and Whitney engines that power our F-16s do not have an electronic throttle control backup if the cable breaks."

Three aircraft maintenance sections within the 57th Maintenance Group sprang into action.

"The 57th MXG pulled together as a team to ensure the wing could accomplish its mission," said Sergeant Stuart.

The Tomahawk AMU, the Viper AMU and the 57th Equipment Maintenance Squadron Phase Inspection Section assembled seven throttle cable change teams. The weapons crews removed the 20 mm gun barrels and the avionics specialists removed associated avionics equipment to allow the crew chiefs to change the cables.

"The required throttle cables and associated hardware were immediately ordered through base supply and thanks to the 99th Logistics Readiness Squadron's outstanding support, they all issued within hours," said Sergeant Stuart.

The teams worked in shifts around the clock removing, replacing and rigging the throttle cables, then performing operational checks on each aircraft.

"All but one of the affected throttle cables were replaced in a mere six days," said Sergeant Stuart. "An amazing feat, considering the average time required to change a single throttle cable is normally two days."

The Time Compliance Technical Order was released Aug. 29, mandating immediate replacement of the throttle cables. By this time, all but one of the throttle cables had already been changed and the aircraft returned to flying status with only 32 sorties lost due to the issue. In fact, on Aug. 30, the F-16 Weapons School was flying a complete training schedule.

"Changing throttle cables happens very rarely," Sergeant Stuart said. "In fact, the AMUs used the last throttle cable as a training event to develop a critical maintenance skill in our crew chiefs. With 24 years of F-16 experience, I have only had the opportunity to perform five throttle cable changes."

"All the separate units in the 57 MXG and 99 LRS joined together to return mission-critical aircraft back to flying and training status. Neither Tomahawk, nor Viper AMUs did this on their own," said Sergeant Stuart. "Everybody helped us out--and if they hadn't, we would still be changing these cables; probably for the next two or three weeks."

Sergeant Stuart further stated, "My job is to generate aircraft for the fighter weapons school, and it's hard to do when the fleet is grounded. There are too many people to thank. We received outstanding support from the 57 EMS Phase team, the Viper AMU, our schedulers, maintainers, maintenance operation center and supply. I am proud to be a part of the 57 MXG team and especially proud to associate with the fine men and women in Tomahawk AMU."