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CHICAGO – The Federal Aviation Administration (FAA) has issued a new inspection mandate affecting hundreds of Boeing aircraft, prompted by concerns over cracks found in some older models. The rule, finalized on Thursday and set to take effect September 10, targets certain planes within the Boeing 737 Max family, specifically the 737-8, 737-9, and 737-8200 variants. According to the FAA, approximately 471 aircraft are subject to this directive aimed at addressing what it calls “an unsafe condition” linked to earlier reports.
While no cracks have been detected in the specified Max models to date, the FAA’s initial proposal last November referenced similar issues found in forward bear straps of several older “Next-Generation” 737 airplanes. Bear straps are structural metal reinforcements located in critical areas such as doorways and emergency exits. Because the Max jets share comparable design and manufacturing processes with these earlier models, the FAA cautioned that they could be vulnerable to the same type of cracking, potentially compromising the aircraft’s structural integrity if left uncorrected.
Boeing responded by noting that it had identified and reported the issue previously and has been collaborating with operators on inspections for the past six years. The company said it provided inspection guidelines for affected Next-Generation 737s as early as 2019, with the FAA mandating those checks in 2021. Boeing also confirmed that it had extended similar inspections to Max jets ahead of the FAA’s recent directive, which now formally requires this process.
“We support both directives and continue to support our airline customers,” Boeing stated.
The FAA’s order further mandates inspections of the fuselage skin in planes that have undergone prior repairs.
This development adds to Boeing’s ongoing challenges with safety, quality, and production. The company has faced intense scrutiny following two fatal crashes involving the 737 Max 8 in 2018 and 2019, which claimed 346 lives, as well as a 2024 incident where a panel detached from a Max 9 aircraft operated by Alaska Airlines during flight. Notably, last month the FAA reinstated Boeing’s authority to self-certify all 737 Max and 787 aircraft, marking a significant step in the company’s regulatory relationship.