CHERRY POINT, N.C. –
Fleet Readiness Center East (FRCE) continues to expand its support of Naval Aviation’s heavy-lift mission with the recent induction of a CH-53K King Stallion engine, the first of its kind to undergo depot-level maintenance.
Following the first induction of a CH-53K helicopter for maintenance at FRCE in April, the facility inducted the platform’s first T408-GE-400 turboshaft engine for depot-level work Sept. 9.
FRCE Engines Branch Head David Thorpe said this induction marks an important milestone in the depot’s support of Naval Aviation.
“Our Maintenance, Repair and Overhaul Production Department and Centralized Coordination Department have been working with the Fleet Support Team, the original equipment manufacturer and other entities for the past few years, and their efforts are beginning to be realized,” Thorpe said. “FRCE is now the only facility in the world that can perform depot-level maintenance on these engines. With this new capability, we can provide the fleet with restored and dependable T408 engine assets, which are much needed as the new CH-53K King Stallion helicopter program continues to grow.”
The T408 turboshaft engine powers the Marine Corps’ CH-53K King Stallion, the U.S. military’s largest and most powerful helicopter. As the heavy-lift replacement for the CH-53E Super Stallion, the King Stallion will expand the fleet’s ability to move more material rapidly throughout the area of responsibility. Powered by three T408 engines, the helicopter can carry 27,000 pounds at a mission radius of 110 nautical miles, nearly triple the baseline of its predecessor, and can lift up to 36,000 pounds externally.
CH-53K Capability Establishment Lead Jeff Warren said the H-53 Heavy Lift Helicopters Program Office has asked FRCE to follow a multi-phase plan to establish full repair capability on the engine. This approach allows FRCE to begin performing limited depot-level maintenance while continuing to develop the processes needed for more in-depth repairs. The current induction represents the first phase of that plan.
“Right now, we are doing what we can and what is needed to get engines back on the shelf for the fleet,” Warren said. “The phased approach allows us to learn more about the engine and develop the repair criteria we need as we move toward conducting more in-depth maintenance on it. We are currently in the repair phase, which consists of inducting engines with specific repair needs. We can disassemble an engine, replace worn and damaged parts with new ones, reassemble and test it.”
As FRCE gains experience and establishes additional repair capabilities, the depot will move into the second and third phases of the plan, Warren said. In those phases, FRCE will be able to overhaul the engine and its components completely.
“We are working to establish full repair capability on the T408,” Warren said. “That includes breaking the engine all the way down, piece by piece, and routing every part of it through our back shops for repairs. We will have the ability to repair and refurbish the parts, rather than having to replace them with brand new ones like we are doing now. Then each part and component will come back to the engine assembly shop, where the engine will be rebuilt and tested.”
To prepare for this induction, FRCE completed multiple pilot repairs on the T408 engine and its components over the past few years to develop and refine repair processes, techniques and materials. During these pilot repairs, FRCE artisans and engineers worked closely with representatives from the original equipment manufacturer and the program management office to learn how to disassemble, reassemble and maintain the engine properly.
Mark Schexnayder, an engine mechanic who participated in many of the pilot repairs, said he is excited to be working on the T408 and looks forward to learning more about the platform.
“We are learning to maintain the new equipment that the military is using so we can continue to support them and their mission for years to come,” Schexnayder said. “I love learning new things, especially when it means I can make more of an impact. Our support of the warfighter is very important, and I am proud to be there for them—from learning everything I can about this engine to now helping to maintain it.”
Warren said FRCE has also been developing a T408 engine test cell that will allow artisans to test an engine’s performance in a controlled environment before returning it to the fleet. Once certified, the test cell will play a critical role in ensuring the engine meets mission requirements and is safe for flight.
“We are the only depot source of repair for T408 engines in the world, which means we are the only site capable of repairing the engines, which also includes testing,” Warren said. “This test cell will be another significant milestone for us. It will allow us to test the engines to make sure they are airworthy and able to support the mission.”
In addition to post-maintenance testing, Warren said the test cell will also be used to assess engines before induction to verify diagnoses and identify any additional repairs needed.
Once FRCE establishes full repair capability, the T408 is expected to represent a significant portion of the depot’s workload.
“Each King Stallion has three engines, which means we are eventually going to have a significant amount of these engines coming through here for depot-level rework,” Warren said. “As of right now, FRCE is projected to eventually induct more than 100 T408 engines per year after we establish full capability. We only did 36 T64 engines in 2024 for the CH-53E Super Stallion because that platform is sundowning.
“FRCE has worked the T64 legacy engines for many years—with the T408 being the engine set to replace the T64, this workload will keep our engine line running well into the future,” Warren said. “In doing this, we are set up to continue to support the warfighter for decades to come, knowing this engine is going to be the future for heavy-lift aircraft.”
Thorpe said this induction is just the beginning of the depot’s support for the CH-53K King Stallion. FRCE plans to establish capability on approximately 150 components and dynamic components for the platform.
“This is just the tip of the iceberg,” Thorpe said. “We are still in the beginning stages of engine and component work for the T408, which will grow exponentially in the next few years. As the King Stallion continues to replace the CH-53E Super Stallion, we will see more and more of these engines and their components come through our shops and more King Stallion aircraft in our hangars. We are proud to be able to provide the fleet with these initial rework services now but are excited to grow and make an even larger impact on fleet readiness in the future.”
Samantha Morse is a public affairs specialist with Fleet Readiness Center East, Cherry Point, North Carolina. 