On Aug. 30, 2001, TAV-8B BUNO 163196 was inducted at Fleet Readiness Center East for the first T-Up modification. The TAV-8B’s were originally built in a joint venture between Boeing Aerospace and British Aero. Boeing manufactured the forward half and British Aero manufactured from Frame 19 aft. As a result of this unusual joint venture, both Boeing and British Aero provided concurrent engineering support to the Cherry Point artisans working on the program. Their support was extremely beneficial during the first few aircraft.

The T-Up Program was such a large undertaking, it was originally divided into three separate phases. Phase I was performed on the first four inductions. It involved an extensive and comprehensive wire bundle replacement on nearly 100 percent of the fuselage and wing wiring. All the Kapton wiring was removed and replaced with a much more reliable and durable Teflon coated product. Phase II was performed on the next two aircraft, which added the engine upgrade from the old F406 to the newer, more efficient and powerful F408. The original Phase I aircraft were later re-inducted and the engine upgrade incorporated.

Along with the T-Up work, several modifications were also incorporated concurrently. Some of these included the centerline fuel tank structural modification, replacement of Frame 12, and the cockpit night-vision lighting modification. Many aircraft also received their PMI-1 repairs in conjunction with the T-Up work. FRC East artisans worked diligently, ensuring these aircraft were brought up to current configuration to provide the fleet with much needed assets.

The artisans working on the AV-8 line have produced 16 upgraded TAV-8B’s and returned them to the fleet since the inception of the program. The final bird, BUNO 163191, was inducted in November 2007 and completed all the necessary repairs/ modifications in December 2010. Tom Warner, current Shop 95774 supervisor, said the final T-Up presented many challenges due to some major structural repairs requiring extensive engineering support. The AV-8 artisans performed their customarily high standards of professionalism throughout the nine-year project. Due to their diligence, the Marine Harrier fighting force is better prepared to train future AV-8B pilots in the aircraft coming out of FRC East.

NAVAIR press release