FAA Orders Inspections of Boeing 737 Max Jets for Fuselage Cracks

The US Federal Aviation Administration (FAA) has ordered inspections of Boeing 737 Max jets for possible fuselage cracks. This affects 471 US-registered Boeing 737 Max aircraft.

The airworthiness directive takes effect on September 10, 2026, and requires inspections of Boeing 737-8, 737-9, and 737-8200 aircraft.

Inspections Ordered Over Bear Strap Crack Concerns

Cracks were found in the bear strap of older Boeing 737 aircraft. This component is a structural reinforcement that supports the fuselage around the aircraft’s exit doors. While no cracks have been found on the 737 Max, it incorporates a similar bear strap design, prompting the FAA to require inspections.

According to the FAA, without action, this could “lead to the inability of a principal structural element to sustain limit loads and adversely affect the structural integrity of the airplane”.

A Boeing spokesperson said the company has been working with airlines operating the affected 737s since identifying the issue in 2019.

On Thursday, the spokesperson said, “The FAA airworthiness directive published today mandates the inspections, as it did for the 737 Next Generation.” The Boeing spokesperson added, “We support both directives and continue to support our airline customers.”

Boeing said the inspections are designed to detect and correct damage before any cracks reach a critical length. It has also changed its manufacturing process to address the underlying cause in aircraft currently in production.

The FAA estimates the initial visual inspection will take one work-hour and cost about $85 per aircraft. For the 471 affected aircraft, the initial inspection alone could cost airlines an estimated $40,035. However, a more detailed inspection could require four work-hours per aircraft, for a total estimated cost of $160,140. These estimates do not include repair costs.

737 Max Jet Issues

Boeing has faced heightened scrutiny following multiple safety incidents involving the 737 Max. In 2024, a door plug blew out during an Alaska Airlines flight, while two fatal crashes in 2018 and 2019 led to the aircraft’s worldwide grounding.

The latest FAA directive comes less than a month after the agency proposed a separate airworthiness directive requiring inspections of seat installations on 737 Max aircraft. The concern is that improperly installed seats could come loose during turbulence or an emergency landing.