B747 Total Refurbishment Costs

Detailed overview of the total refurbishment costs for a Boeing 747-400 (B744) to the premium cabin spec you described — including cabin retrofit, landing gear overhaul, APU overhaul, and engines overhaul/replacement.

Boeing 747-400 Refurbishment Cost Breakdown

ItemDescriptionEstimated Cost (€ million)
1. Cabin RefurbishmentFull premium interior fit-out: First & Business class seats, galleys, lavatories, wiring, lighting, in-flight entertainment, finishes8.0 – 12.0
2. Landing Gear OverhaulComplete overhaul of main and nose gear (struts, brakes, wheels, actuators) including testing and certification0.8 – 1.2
3. Auxiliary Power Unit (APU)Overhaul or replacement (Honeywell 131-9A or similar)0.5 – 0.65
4. Engine Overhaul / Shop VisitGeneral Electric CF6-80C2 or PW4000 engines; includes hot section inspection, compressor, turbines, balancing, and performance restoration.
Full shop visit		4.0 – 6.0 (per engine (x4))
= 16.0 – 24.0
5. Systems & Avionics UpdatesUpdates/repairs to avionics, wiring harnesses, galley systems, and cabin management systems1.0 – 2.0
6. Paint & ExteriorComplete aircraft strip and repaint, including corrosion treatment1.0 – 2.0
7. Structural Checks & RepairsDetailed structural inspections, repairs, modifications as needed4.3 – 4.6

Total Estimated Refurbishment Cost

ScopeEstimated Range (€ million)
Cabin + Systems8.0 – 12.0
Landing Gear0.8 – 1.2
APU0.5 – 0.65
Engines (4× overhaul)16.0 – 24.0
Paint & Exterior1.0 – 2.0
Structural & Others4.3 – 4.6
Total30 – 45 million €

Additional Notes:

  • Engines are the single largest cost driver — shop visit by US Specialist.
  • Full cabin refurbishment to a premium spec with bespoke First & Business class seats is expensive, especially with installation and certification.
  • Landing gear overhaul is mandatory within certain cycles and/ or age — high cost but critical for safety and operational approval.
  • APU overhaul is usually necessary when performing major maintenance. Better: New APU!
  • Paint and corrosion control prevent future maintenance and preserve resale value.

Upon further research, I’ve found that Aerospace Rotables, in partnership with SEMAN MRO, offers comprehensive landing gear overhaul services for various Boeing aircraft models, including the 747.

🔧 Aerospace Rotables – Landing Gear Overhaul Services

  • Location: Sunrise, Florida, USA
  • Facility: A 150,000 sq ft landing gear MRO facility
  • Certifications: FAA/EASA certified
  • Capabilities:
    • In-house plating
    • CNC-controlled machining
    • Shot peening
    • Non-Destructive Testing (NDT)
    • Painting
  • Services Offered:
    • Landing gear overhaul
    • Exchange and loan programs
    • Outright sale
    • Modification services
  • Aircraft Supported:
    • Boeing 747
    • Boeing 757
    • Boeing 767
    • Boeing 777
    • Boeing 737NG/Classic
  • Contact Information:

Aerospace Rotables emphasizes an all-inclusive pricing model with no hidden fees, aiming to provide cost-effective solutions and reliable turnaround times. They manage the entire overhaul process in-house, ensuring consistent quality and minimizing delays.(Aerospace Rotables)

TIME FRAME

Boeing 747-400 Full Refurbishment Timeframe Estimate

PhaseDescriptionDuration (Weeks)
1. Planning & EngineeringDesign finalization, certification prep, scheduling4 – 6
2. Aircraft Entry & InspectionInitial detailed inspection, damage assessment1 – 2
3. Cabin RefurbishmentRemoval of old cabin, installation of new seats, wiring, IFE, lavs, galleys12 – 18
4. Landing Gear OverhaulRemoval, overhaul, testing, reinstallation6 – 8 (can overlap)
5. Engine Shop VisitsEach engine off-wing for overhaul (can be staggered/parallel)8 – 12 per engine (engines staggered to minimize downtime)
6. APU OverhaulOverhaul or replacement3 – 5
7. Systems & Avionics UpdatesInstallation and testing4 – 6
8. Paint & ExteriorStripping old paint, corrosion treatment, new paint3 – 5
9. Structural Repairs & Final ChecksFinal inspections, non-destructive testing, repairs2 – 4
10. Certification & Test FlightsRegulatory inspections, flight tests, documentation2 – 4

Total Estimated Downtime:

  • Without engine shop visit concurrency: ~36–48 weeks (9–12 months)
  • With optimized engine shop visit overlap and parallel work: ~30–36 weeks (7–9 months)

Notes:

  • Engine shop visits are usually the critical path but can be staggered or contracted to different shops to reduce total downtime.
  • Some tasks (like landing gear overhaul, cabin retrofit, avionics updates) can run in parallel.
  • Unexpected findings during inspection or structural repairs can extend timeline.
  • Availability of parts, skilled labor, and certification authorities’ scheduling can influence overall time.

Adresses:

Contact details for Joramco and Aerospace Rotables:

Joramco (Jordan Aircraft Maintenance Limited)

Aerospace Rotables, Inc.