The Federal Aviation Administration (FAA) has issued a mandatory fuselage inspection order for 1,900 Boeing 737 jets, including certain 737 Max 8, Max 9, and 737-200 models, following the discovery of cracks in structural components of older 737 aircraft.
The directive, issued on Thursday, applies to 471 planes in the U.S. and 1,429 planes worldwide, according to the FAA. While no cracks have been found in the 737 Max fleet to date, the inspections aim to preemptively identify and address potential structural weaknesses before they escalate into safety concerns. The FAA’s order sets a clear timeline for compliance, requiring operators to conduct the checks and complete any necessary repairs within the specified period.
The cracks were detected in a component known as the bear strap, which reinforces areas around doorways and emergency exits. The FAA attributed the issue to repeated stress from takeoffs and landings, which can cause fatigue in metal over time, particularly near door corners. The agency emphasized that the inspections are proactive measures to ensure structural integrity across the fleet.
Boeing’s Response and Timeline of Awareness
Boeing confirmed in a statement that it first alerted operators of its 737 Next Generation (NG) planes to this issue in 2019, providing detailed inspection guidelines. The company noted that while the problem had not been observed in the 737 Max series, it extended the inspection protocol to Max aircraft in 2024 due to their shared design and manufacturing processes with the NG models.
Boeing stated it is conducting further analysis to determine the root cause of the cracking and to implement measures to prevent similar issues in future aircraft. The company did not specify whether the cracks were linked to a specific manufacturing defect, design flaw, or operational stress factor.
Airlines Prepare for Compliance
Southwest Airlines, one of the largest operators of 737 jets in the U.S., responded to the FAA’s directive by stating it was reviewing the airworthiness order and would complete the required inspections according to the FAA’s schedule. The airline did not provide additional details on the timeline or scope of its preparations.
Scope and Impact of the Inspections
The FAA’s inspection mandate covers a broad range of 737 models, including:
- 737 Max 8
- 737 Max 9
- 737-200 (older generation)
The inspections will focus on the forward service door area near the galley on the right side of the fuselage, where the bear strap reinforcement is located. Operators are expected to report findings to the FAA, which will assess whether additional corrective actions are necessary.
The FAA has not indicated whether the inspections will lead to groundings or operational restrictions, but emphasized that the goal is to maintain fleet safety through early detection and repair. The agency did not provide an estimated timeline for when the inspections might be completed across the global fleet.