Fuel Cell Mechanic

Fuel Cell Mechanic

This role focuses on the removal, installation, inspection, and repair of aircraft fuel cells, bladders, and related components. You will work from technical documentation to perform precise assembly and disassembly operations on aircraft fuel systems, diagnose and correct leaks, and ensure all work meets strict quality and safety standards. The position requires hands-on mechanical skills, attention to detail, and the ability to operate specialized tools and ground support equipment in a production or maintenance environment.

Responsibilities

• Perform removal, installation, and inspection of aircraft fuel cells, bladders, fuel lines, hardware, fittings, and related components in accordance with established procedures.
• Analyze aircraft sealing, structural, and assembly drawings to identify sealing deficiencies and ensure compliance with design requirements.
• Diagnose and interpret results of fuel system leak tests to detect drawing, specification, structural, and assembly sealing errors.
• Recommend and implement corrective actions to resolve fuel system deficiencies and ensure leak-free performance.
• Perform disassembly and teardown operations on aircraft fuel systems and related components, following detailed technical instructions.
• Remove fuel cells and components from aircraft using specific procedures and techniques to prevent damage and ensure safety.
• Prepare cavities and internal structures for installation of fuel cells and components, ensuring cleanliness and proper condition of internal fittings.
• Install fuel cells and components using approved methods, procedures, and techniques, and verify correct installation.
• Use appropriate pressure test equipment to perform fuel system tests and make repairs as required to meet specifications.
• Inspect fuel cells for damage and assess cavity conditions, including internal fittings and structural features, to ensure readiness for service.
• Work from operation sheets, diagrams, blueprints, engineering orders, military specifications, and verbal instructions to complete assignments accurately.
• Perform assembly and disassembly operations on aircraft fuel systems and equipment in accordance with Department of Defense, manufacturer, company, supplier, and other directives.
• Conduct operational checks of aircraft fuel systems and components with or without production aids to verify proper function.
• Assemble and test articles for use in system testing, development, and modification of aircraft fuel systems.
• Maintain production schedules and quality standards by completing tasks efficiently and accurately.
• Check completed work for completeness, accuracy, and compliance with applicable standards and documentation.
• Notify supervision of any malfunctions, defects, or damage related to equipment, materials, and products encountered during work.
• Keep the work area clean, orderly, and compliant with safety and tool control requirements.
• Assist other aircraft mechanics as required and perform related duties incidental to the completion of assignments.
• Order parts, pan stock, tools, materials, and equipment as needed while performing assigned duties.
• Comply with all rules and regulations concerning health and safety, tool control, contracts, facilities, and other applicable requirements.

Essential Skills

• 2 to 4 years of experience performing duties related to aircraft fuel systems, fuel cells, and fuel component overhaul.
• Hands-on experience as a fuel cell mechanic working on aircraft fuel systems and aircraft fuel components overhaul.
• Ability to read and interpret schematics, assembly drawings, process specifications, technical manuals, written instructions, and test procedures.
• Proficiency in using a variety of precision measuring instruments such as torque wrenches, gauges, and measuring devices.
• Ability to work effectively with hand tools and pneumatic tools in a maintenance or production environment.
• Ability to operate various ground support equipment including hydraulic test carts, nitrogen/oxygen carts, tow tractors, and hangar deck cranes.
• Capability to fuel, defuel, pencil drain, and leak check aircraft fuel systems safely and accurately.
• Ability to work in confined spaces while performing fuel system maintenance and inspections.
• Ability to remove and install equipment and components using blueprints with firm callouts, including butt, center, chord, station, and water lines.
• Skill in identifying different types of corrosion and performing appropriate cleaning and treatment.
• Strong oral and written communication skills to interact with coworkers, supervision, and other personnel as required.
• Ability to clearly document maintenance and repair actions, equipment status tags, logs, and parts requests.
• Ability to perform assigned duties while wearing required safety equipment and personal protective gear.
• Ability to perform duties on all shifts without encumbrances due to weather, physical location, or facility conditions.
• Knowledge of shop mathematics, assembly methods, and standard shop practices.
• Ability to work from drawings, sketches, sample parts, position templates, and other complete or incomplete information.

Additional Skills & Qualifications

• Experience working to Department of Defense, manufacturer, company, and supplier directives for aircraft fuel systems.
• Familiarity with military specifications (mil-specs) and engineering orders related to aircraft fuel systems.
• Experience maintaining schedules and quality standards in a production or maintenance environment.
• Strong attention to detail with a focus on leak prevention and fuel system integrity.
• Demonstrated ability to keep work areas clean, organized, and compliant with safety and tool control procedures.
• Comfort working in open-bay, non-climate-controlled environments.
• Flexibility to support other mechanics and perform additional related duties as assignments require.

Why Work Here?

You will join a team that values technical excellence, safety, and craftsmanship in aircraft maintenance and modification. The role offers the opportunity to deepen your expertise in complex fuel systems while working with advanced tools and ground support equipment. You will benefit from a structured environment with clear procedures, strong emphasis on quality, and opportunities to expand your skills across different aircraft programs. The position also offers pathway opportunities to transition to major aerospace organizations after demonstrating strong performance over time.

Work Environment

This position operates in an open-bay, non-climate-controlled hangar environment where temperatures and conditions may vary with the weather. Work is performed on 1st shift (Monday to Friday, approximately 5:30 a.m. to 2:30 p.m.) and 2nd shift (Monday to Friday, approximately 2:00 p.m. to 10:30 p.m.), with optional overtime, and you must be open to working any shift as assigned. You will regularly use hand and pneumatic tools, precision measuring instruments, pressure test equipment, and ground support equipment such as hydraulic test carts, nitrogen/oxygen carts, tow tractors, and hangar deck cranes. Duties often involve working in confined spaces within aircraft fuel cavities while wearing required safety equipment and personal protective gear. The environment emphasizes strict adherence to health and safety rules, tool control, and facility regulations. A steel-toed shoe allowance is available, with the ability to expense a portion of the cost each year, and a clean, orderly work area is expected at all times.

Job Type & Location

This is a Contract to Hire position based out of San Antonio, TX.

Pay and Benefits

The pay range for this position is $35.00 - $40.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:

• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in San Antonio, TX.

Application Deadline

This position is anticipated to close on Jun 30, 2026.