Dismantling a Beast: UK Wrestles with F-35B’s Complexity on Foreign Soil in Kerala

On July 6, a Royal Air Force A400M Atlas brought in a 25–40 member team of engineers and Lockheed Martin-certified technicians to Thiruvananthapuram.

A British Royal Navy F-35B stealth fighter jet, stranded at Thiruvananthapuram International Airport since June 14, 2025, is now set to be dismantled and flown back to the United Kingdom. The jet, grounded by an unresolved hydraulic failure, cannot be repaired locally due to its complex systems and the absence of F-35 maintenance infrastructure in India. A C-17 Globemaster III military aircraft will likely transport the disassembled jet to the UK for restoration.

Why the Jet Must Be Moved

Efforts to fix the jet’s critical hydraulic system in India proved unsuccessful. The F-35B’s advanced design includes classified technologies like radar-absorbing coatings, encrypted software, and AI-based combat systems—requiring tools and expertise available only at select certified locations. India does not operate the F-35, and no repair base exists in the region.

Beyond technical hurdles, national security concerns make it risky to leave the jet parked at a civilian airport. The aircraft is part of the HMS Prince of Wales Carrier Strike Group, and its prolonged absence weakens the UK’s operational readiness. Transporting it back is the only viable and secure option.

UK Sends a Specialized Team

On July 6, a Royal Air Force A400M Atlas brought in a 25–40 member team of engineers and Lockheed Martin-certified technicians to Thiruvananthapuram. The team brought specialized tools and a tow vehicle, starting with an inspection to assess whether repairs could be done on-site. Once confirmed unrepairable, the dismantling process began.

Moving to a Safer Location

Initially, the F-35B was parked in the open at Bay 4 of the airport under CISF security. The UK declined to move it to a hangar due to concerns over exposure of sensitive systems in a non-NATO country. However, with India’s assurances and growing urgency, the jet was shifted to a secure Maintenance, Repair, and Overhaul (MRO) facility where the environment is controlled and access is tightly restricted.

The Dismantling Process

Removing the jet’s wings, tail fins, and stabilizers is essential to fit it inside the C-17’s cargo bay, which is 26 meters long but only about 4 meters wide. The F-35B has a wingspan of nearly 10.7 meters, making disassembly the only option.

This process is far from simple. Every screw, bolt, and panel is security-coded and logged to prevent tampering or unauthorized access. Only Lockheed Martin-trained engineers are allowed to perform these tasks. The dismantled components are carefully packed to avoid damage to the stealth coatings or internal systems.

The jet’s fuselage is then compacted and prepared for loading as a single unit, taking care to protect the aircraft’s sensitive sensors and onboard electronics.

Airlift to the UK

Once dismantled, the aircraft will be loaded onto a Royal Air Force C-17 Globemaster III—one of the few transport aircraft capable of handling such a load. Technicians will supervise the process to ensure that the jet’s frame and sensitive systems remain intact.

The aircraft will likely be flown to RAF Marham in the UK, where full-scale repair facilities for the F-35 are located. Once there, it will be reassembled and thoroughly tested before rejoining active service aboard HMS Prince of Wales.

Security and Diplomatic Coordination

Throughout the dismantling and transport operation, UK Royal Air Force personnel and naval officers are maintaining strict security. They are working in coordination with Indian CISF forces to prevent any technology leaks or unauthorized access.

The UK government has also committed to settling all dues, including parking and hangar charges, with Indian authorities. The diplomatic coordination between the two nations has been smooth, despite early hesitation regarding the hangar shift.

Challenges Faced

The operation has not been without complications:

• Security Sensitivities: Concerns over espionage led to initial delays in moving the aircraft to a hangar.
• Weather Conditions: Exposure to Kerala’s heavy monsoon rains added further urgency and risk to the already delicate dismantling process.
• Public Curiosity: The jet’s unexpected stay captured widespread attention, sparking social media memes and even a cheeky post from Kerala Tourism.

Past Examples

This is not the first time an F-35 has had to be dismantled. In 2019, the US Air Force removed the wings of an F-35A for transport from Florida to Utah. Similarly, in 2022, South Korea transported a belly-landed F-35A by road after removing its wings. These precedents show that such operations are technically feasible and already tested.

Why On-Site Repairs Weren’t Possible

The hydraulic failure affecting this particular jet requires diagnostic equipment, spares, and expertise not available in India. As India doesn’t operate any F-35s, it lacks the maintenance infrastructure needed for even minor repairs. Returning the jet to the UK is the only way to ensure it is properly restored and returned to duty.

Conclusion

The mission to dismantle and fly back the UK’s F-35B from India is more than just a technical exercise—it is a symbol of careful international coordination, the importance of protecting advanced defense technologies, and the logistical precision required to handle one of the world’s most advanced fighter jets. Once it takes to the skies again from British soil, the F-35B will carry with it a fascinating chapter from Kerala that blended diplomacy, engineering, and a touch of global intrigue.

—— E.O.M 

( Girish Linganna is an award-winning science communicator and a Defence, Aerospace & Geopolitical Analyst. He is the Managing Director of ADD Engineering Components India Pvt. Ltd., a subsidiary of ADD Engineering GmbH, Germany. Contact: girishlinganna@gmail.com )