FAA mandates inspections of 471 Boeing 737 MAX jets for fuselage cracks

The U.S. Federal Aviation Administration has issued an Airworthiness Directive requiring inspections of approximately 471 U.S.-registered Boeing 737 MAX aircraft for potential cracks in the bear strap, a structural reinforcement component located near the forward galley door. The directive, effective September 10, 2026, applies to 737 MAX 8, MAX 9, and MAX 8-200 variants. Airlines must inspect the fuselage paneling on a schedule based on each aircraft's operational usage and repair any identified cracks before returning the plane to service.

The FAA stated that undetected damage in this structural component could reduce the aircraft's ability to sustain limit loads and adversely affect overall structural integrity. No cracks have been found in 737 MAX models to date. The directive follows reports of similar cracks discovered in older Boeing 737 Next Generation aircraft (737-700, 737-800, 737-900), which led to FAA-mandated inspections in 2021. The MAX variants share comparable design and manufacturing processes with the older 737 NG models, making them susceptible to the same condition.

Boeing stated it identified the issue and began working with airline operators in 2019. The company sent inspection instructions to operators of affected 737 NG aircraft in 2019, and has since expanded those inspections to MAX jets. Boeing is conducting engineering analysis to determine the root cause and is developing engineering changes to prevent future occurrences. The FAA noted that the required inspection intervals provide multiple opportunities to detect cracks before they could compromise structural integrity, and did not ground the aircraft. The directive also requires inspections of fuselage skin on planes with existing repairs.

This inspection mandate is one of several recent safety directives affecting Boeing's fleet. Last month, the FAA proposed an additional airworthiness directive requiring inspections of seat assemblies on 453 Boeing 737 MAX jets due to potential incorrect installation. The inspections come amid broader scrutiny of Boeing's safety and manufacturing practices following the January 2024 Alaska Airlines incident in which a door plug blew out of a 737 MAX 9 midflight, and earlier fatal crashes in 2018 and 2019 that killed 346 people.