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C-40A Clipper
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The 737 based C-40 Clipper represents a substantial upgrade over the 1970s-era, DC-9 based C-9 Skytrains and 727-based C-22Bs that have performed its transport roles to date. The C-9s are still in service with the US Naval Reserve and USAF, but they’re expected to be be phased out as the C-40s take up the load.

Meanwhile, concern has been expressed about the funding levels for this replacement program, as well as the USAF and US Navy C-9 fleet’s continued durability. The USAF’s C-9A models are of particular concern.

The C-40 comes in 3 variants; the C-40A is a Navy aircraft, while its counterpart C-40C and executive C-40Bs are USAF planes. The USAF’s C-40 leasing contracts have been a source of some controversy, but the program has continued, and the US Navy has just bought a pair of additional aircraft for its fleet…

• The C-40 Programs
• Contracts and Key Events
• Additional Readings

The C-40 Programs

C-40A loading
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To create a C-40, the 737-700C airframe is modified with a large cargo door, and the strengthened wings and landing gear of the 737-800. The resulting aircraft has a range of 3,400 nautical miles with 5,000 pounds of cargo, and can carry up to 40,000 pounds. A fully digital “glass” cockpit allows for future growth and is also fitted with a head-up display. Another major improvement is the GPS in its navigation system, which aids in airport approaches within Third World countries who possess older, less reliable ground systems.

The U.S. Naval Reserve Fleet Logistics Support Wing operated 29 of the old DC-9 based C-9B Skytrain Combi aircraft (90 passengers, 30,000 pound limit, shorter range than C-40A), providing high-priority cargo and passenger airlift for the U.S. Navy fleet worldwide. The aircraft were operated by 7 Naval Reserve units nationwide, and provided 85% of the worldwide airlift requirements for the entire Navy.

The Navy’s C-40A replacements were initially ordered and delivered with standard wings, but airline usage has shown significant fuel-savings benefits from adding turned-up “winglets” on the end. New-build C-40As from aircraft #9 onward will now have those winglets, C-40As #5-8 have been retrofitted, and a decision concerning retrofits for aircraft #1-4 is expected in spring 2009.

C-40B, delivered
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The USAF is replacing its C-9As, and its 4 727-derived C-22Bs.

The USAF C-40Bs operate as an “office in the sky” for senior military and government leaders. C-40Bs are equipped with the Connexion system, providing secure in-flight broadband connectivity that includes data/video transmit and receive capability. Its visual profile matches the C-40C’s and new-build C-40As, with turned up winglets. Boeing delivered the last C-40B in 2005.

The C-40C is the USAFs counterpart to the Navy’s C-40A. Both types are certified to operate in one of 3 configurations: an all-passenger (121) configuration; an all-cargo configuration of up to 8 pallets; or a combination, or “combi” configuration that will accommodate up to 3 cargo pallets and 70 passengers. Unlike its C-40A counterpart, the C-40C has always used the common 737-700 configuration with turned-up winglets.

To date, orders have been placed for 20 C-40 family aircraft: 11 Navy C-40As, 4 USAF C-40Bs, and 6 USAF C-40Cs. A June 2006 release from Boeing has said that the US Navy plans to expand its C-40 fleet size over time, and may buy up to 32 aircraft; but 2008 NAVAIR releases place the planned total at 18.

Contracts and Key Events

USAF C-40C
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Dec 15/08: Boeing receives a $136.1 million firm-fixed-price contract from the US Navy for 2 C-40A Clipper aircraft, which would bring the Navy’s C-40A fleet to 11 aircraft. These aircraft will use the Navy’s new configuration, with turned-up winglets on the ends of the wings.

Work will be performed in Renton, WA (88%); and Wichita, KS (12%) and is expected to be complete in February 2011. This contract was not competitively procured, pursuant to FAR 6.302-1. The Naval Air Systems Command in Patuxent River, MD manages this contract (N00019-09-C-0080). NAVAIR release.

Nov 28/07: L-3 Communications Corp. in Arlington, TX received $17 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract (N00019-04-D-0110), exercising an option for logistics support to the Navy’s C-40A fleet. Work will be performed in Fort Worth, TX (22%); Jacksonville, FL (22%); North Island, CA (22%); Oklahoma City, OK (20%); Arlington, TX (8%); and Tulsa, OK (6%), and is expected to be complete in November 2006. The Naval Air Systems Command in Patuxent River, MD issued the contract.

Services to be provided include site activation; site support; inventory management and support; depot level support (scheduled and unscheduled); drop-in maintenance; component repair and overhaul of government and contractor-owned inventory; contractor field teams; replacement of government and contractor-owned inventory; and engine condition monitoring.

Nov 2/06: L-3 Communications Corp., Arlington, Texas, is being awarded an $18.2 million modification to a previously awarded indefinite-delivery, indefinite-quantity contract (N00019-04-D-0110) to exercise an option for logistics support services for the Navy’s C-40A aircraft fleet. Work will be performed in Fort Worth, TX (22%); Jacksonville, FL (22%); North Island, CA (22%); Oklahoma City, OK (20%); Arlington, TX (8%); and Tulsa, OK (6%), and is expected to be complete in November 2006. The Naval Air Systems Command in Patuxent River, MD issued the contract.

Services to be provided include site activation; site support; inventory management and support; depot level support (scheduled and unscheduled); drop-in maintenance; component repair and overhaul of government and contractor-owned inventory; contractor field teams; replacement of government and contractor-owned inventory; and engine condition monitoring.

HI, Bye: VP-4 Departs
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May 25/06: Boeing never announced the Navy’s order of a 9th C-40A Clipper transport aircraft, but the plane is delivered to Squadron VR-57 of the Naval Reserve’s Fleet Logistics Support Wing, 36 days ahead of schedule. The plane is the first C-40A to be built with turned-up winglets on the ends of its wings.

March 10/06: Boeing in Seattle, WA received a $76.4 million firm-fixed-price contract modification to fund the annual C-40 and C-32 contractor integrated fleet support contract through calendar year 2006. At this time, $30.6 million has been committed. The Headquarters Aeronautical Systems Center at Wright-Patterson Air Force Base, OH manages this contract (F33657-01-D-0013/ no modification # announced).

Nov 29/05: L-3 Communications Corp. in Arlington, TX receives a $20 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract (N00019-04-D-0110), exercising an option for logistics support services to the US Naval Reserve’s C-40A Clipper aircraft fleet.

Services to be provided under L-3’s most recent C-40A support contract include site activation; site support; inventory management and support; depot level support (scheduled and unscheduled); drop-in maintenance; component repair and overhaul of government and contractor-owned inventory; contractor field teams; replacement of government and contractor-owned inventory; and engine condition monitoring.

Work will be performed in Fort Worth, TX (22%); Jacksonville, FL (22%); North Island, CA (22%); Oklahoma City, OK (20%); Arlington, TX (8%); and Tulsa, OK (6%), and is expected to be complete in November 2006. The Naval Air Systems Command in Patuxent River, MD issued the contract.

C-9C and C-40C
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Feb 14/05: GovExec reports that the USAF’s C-40 lease contracts have been referred to the Investigator General as part of the Darlene Druyun influence-peddling scandal.

Dec 4/04: L-3 Communications Corp. in Arlington, TX receives a $20.4 million indefinite-delivery/ indefinite-quantity contract (N00019-04-D-0110), exercising an option for logistics support services to the US Naval Reserve’s C-40A Clipper aircraft fleet. Work will be performed in Fort Worth, TX (33%); Jacksonville, FL (33%); Oklahoma City, OK (20%); Arlington, TX (8%); and Tulsa, OK (6%), and is expected to be complete in November 2006. The Naval Air Systems Command in Patuxent River, MD issued the contract.

Services to be provided include site activation; site support; inventory management and support; depot level support (scheduled and unscheduled); drop-in maintenance; component repair and overhaul of government and contractor-owned inventory; contractor field teams; replacement of government and contractor-owned inventory; and engine condition monitoring.

Nov 22/04: The 7th C-40A Clipper aircraft is delivered to the US Navy.

July 23/04: A 2004 release by Sen. Richard Durbin [D-IL] and Congressmen Jerry Costello [D-IL] and John Shimkus [R-IL] touts their success in securing money for C-40s at a local air base, in order to keep it open.

The letter illustrates some of the ongoing issues around C-40 fleet size, funding, local interest, et. al. with hard dollar figures.

Nov 24/03: Boeing announces that the U.S. Navy has ordered an 8th C-40A Clipper for its Unique Fleet Essential Airlift Replacement Aircraft program.

Boeing’s release adds that the US Naval Reserve provides line maintenance on the C-40A aircraft, while Boeing and its industry partner Delta Air Lines are on contract for 3 years of initial logistics support providing site support, spares management and heavy maintenance.

Sept 17/02: Boeing received a $217.7 million firm-fixed-price contract from the Headquarters Aeronautical Systems Center at Wright-Patterson Air Force Base, OH to lease up to 4 C-40 aircraft (F33657-02-C-0017).

It also received a $52.6 million firm-fixed-price contract modification that added ordering provisions for Contractor Logistics Support for up to 4 C-40 series leased aircraft (F33657-01-D-0013, P00014). Total: $270.3 million.

July 23/02: Rep. Curt Weldon, Chairman of the House Committee on Armed Services Subcommittee on Military Procurement, is presented with an interesting July 2002 Congressional Budget Office analysis covering the USAF’s decision to lease its C-40 aircraft. The CBO concludes that the difference between the leasing deals and outright purchase of the aircraft was quite small, and questions the choice.

Aug 06/01: Boeing announces a C-40 aircraft order from the USAF to begin replacing 4 US Air National Guard 727-derivative C-22B aircraft that were manufactured in the mid-1960s, and acquired in the mid-1980s. This is the 2nd C-40 aircraft ordered by the USAF under the contract established with Boeing in February 2001.

With an interior configuration identical to the C-40B platform, the aircraft will be used to improve the Air National Guard’s capability for rapid response to team travel and special air mission tasking.

Jan 03/01: Boeing announces that the U.S. Navy has ordered a 6th C-40A for its Navy Unique Fleet Essential Airlift Replacement Aircraft (NUFEA-RA) program.

At this point in the Navy’s program, 2 C-40As are at Boeing in Wichita, KS for modifications that allow the aircraft to be operated in the combi mode. A 3rd aircraft has completed flight testing and will be flown to Wichita for modifications. A 4th is expected to join it in February 2002, and Flight Safety Boeing is training Naval Reserve flight crews and maintenance technicians.

Feb 9/01: Boeing wins an $800 million firm-fixed-price contract to provide for up to 7 C-40 aircraft, and up to 10 years of associated contractor logistics support.

The contract has provisions that can allow for incorporation of the contractor logistics support effort for the USAF’s 757-derivative C-32 aircraft into this contract. The Aeronautical Systems Center at Wright-Patterson AFB, OH issued the contract (F33657-01/D-0013).

Sept 09/ 2000: Boeing rolls out the first C-40A Clipper for the U.S. Naval Reserve, at a festive celebration held at Boeing Field in Seattle. Boeing release.

June 10/1998: Boeing announces that the U.S. Navy has exercised its option for a 3rd C-40A, under its Navy Unique Fleet Essential Airlift Replacement Aircraft (NUFEA-RA) program. The Navy has ordered 2 of the 737-700C derivatives in September 1997, with an option to purchase a 3rd.

The contract, valued at $163 million, calls for deliveries to the Commander Naval Air Reserve Forces to begin in December 2000.

Additional Readings

• Boeing – C-40A Clipper Military Transport. Operated by the US Navy.

• Boeing – C-40B Special-Mission Aircraft, USAF: Provides airlift with an office-in-the-sky environment for U.S. combatant commanders and other senior government officials. C-40Bs are equipped with the Connexion by Boeing system, providing secure in-flight broadband connectivity.

• Boeing – C-40C Operational Support and Team Travel Aircraft. USAF Reserve.