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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, it will be necessary to understand how crew repair and maintenance timelines are impacted by mission operations and technology changes. Past work has been done using historical 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 data sets, to extrapolate from that data to estimate projected maintenance and repair times for a lunar Surface Habitat, and to assess how uncertainty in repair time could impact utilization time on the lunar surface. NASA International Space Station (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) respectively. 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. MDC provides a detailed catalog of failure events and an overview of the failure’s required maintenance and OPTimIS provides a description of crew activities and crew time durations dedicated to maintenance. 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 times for each failure event. Data is also classified by the outcome of each repair event, whether the failed component was replaced or whether it was repaired in place. The entire maintenance activity dataset is then categorized based on the class of failed component to allow for a statistically significant sample size for each class and to provide 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. Repair time distributions can then be used to develop more accurate crew schedules and to assess potential available utilization time.