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NASA is currently evaluating different methods to predict how much time crewmembers will spend conducting repair and maintenance activities on future space missions. As mission scope and spacecraft architectures change, understanding how crew repair and maintenance timelines are impacted by mission operations and technology changes is vital for future mission planning. Past work has been done using historical International Space Station (ISS) data to accurately predict crew habitation and operation timelines, resulting in the development of NASA’s Exploration Crew Time Model (ECTM). However, understanding crew maintenance and repair requirements has posed a unique challenge due to the complexity of available datasets, the probabilistic nature of sub-system failures, and the impacts of reliability growth on failure rates. This paper presents a methodology to collect and condition empirical repair and maintenance time data from available datasets, to extrapolate from that data to estimate projected maintenance and repair times for a lunar Surface Habitat (SH), and to assess how uncertainty in repair time could impact utilization time on the lunar surface. NASA ISS maintenance and crew time data are logged into two central databases: the Maintenance Data Collection (MDC) and the Operations Planning Timeline Integration System (OPTimIS). Separately, each of these two datasets capture only portions of the complete set of data required to generate an accurate assessment of crew time spent on maintenance activities at a sub-system level. To create a more useful crew time estimate for maintenance timelines, the authors developed a methodology to capture relevant data from each set and combine and utilize that data by linking crew time requirements to specific components. The authors compare the failure logs in the MDC to crew activity logs pulled from OPTimIS and then process the data to estimate required repair time for each failure and repair event. The entire maintenance activity dataset is then categorized based on the class of failed component to ensure a significant sample size for each class and accurate crew time estimates for any components lacking relevant data. This resultant component repair time data can be used in the future to generate Mean Time to Repair (MTTR) estimates and confidence intervals for each class of component based on a probabilistic distribution of documented maintenance events. These improved MTTR values can then be applied to candidate element sub-system architectures, along with component Mean Time Between Failure (MTBF) data to generate distributions for potential required system crew repair time estimates for a given mission. The authors applied these modeling methods to a case study of a crewed mission to the planned SH and produced expected corrective maintenance crew time distributions. The results produced an expected corrective maintenance crew time at over 24 hours per mission, and a maintenance crew time distribution that reflects the importance of planning for sufficient maintenance requirements each mission. Repair time distributions can then be used to develop more accurate crew schedules and to assess potential available utilization time.