The US Federal Aviation Administration (FAA) has ordered mandatory inspections for hundreds of Boeing 737 Max aircraft after reports of cracks in structural components on older Boeing models prompted regulatory action.
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The US Federal Aviation Administration (FAA) has ordered mandatory inspections for hundreds of Boeing 737 Max aircraft after reports of cracks in structural components on older Boeing models prompted regulatory action.
According to reporting by Business Standard, the finalised airworthiness directive was issued this week and will take effect on 10 September. The order applies to specific aircraft within the 737-8, 737-9 and 737-8200 families.
The FAA estimates the directive covers 471 aircraft and said the action is intended to address what it described as an "unsafe condition" linked to previous reports involving similar aircraft structures.
Concerns stem from findings in earlier 737 models
The regulator noted that no cracks have been identified so far in the affected 737 Max aircraft.
However, when proposing the rule in November, the FAA said it had received reports of cracks in a forward bear strap on several older Boeing 737 Next Generation aircraft.
Bear straps are metal reinforcement sheets used around key aircraft structures, including doorways and emergency exits.
According to the FAA, the newer Max aircraft share similar design characteristics and manufacturing processes with the older models where the issue was identified.
The regulator said these similarities could make the affected aircraft susceptible to the same type of cracking.
The FAA further warned that unresolved cracks could negatively affect the aircraft's structural integrity.
Scope of the FAA directive
Under the new rule, operators of affected aircraft will be required to carry out inspections and related checks.
Key elements of the directive include:
The directive formalises inspection requirements that Boeing had already expanded to include Max aircraft.
Boeing says inspections have been underway
In a statement cited by Business Standard, Boeing said it had previously identified the issue and reported it to regulators.
The aircraft manufacturer stated it has been working with airline operators on the matter for the past six years.
According to Boeing:
"We support both directives and continue to support our airline customers," Boeing said in its statement.
Latest challenge in Boeing's long safety recovery
The inspection order arrives as Boeing continues to navigate heightened regulatory oversight and scrutiny of its manufacturing and safety processes.
The company has spent several years addressing the consequences of two fatal 737 Max 8 crashes in 2018 and 2019 that killed 346 people, leading to the global grounding of the aircraft type.
More recently, a 737 Max 9 operated by Alaska Airlines suffered a mid-flight panel blowout in 2024, triggering fresh investigations into Boeing's production quality controls.
At the same time, the company has been working with regulators to restore confidence in its certification and manufacturing systems.
According to Business Standard, the FAA said last month that Boeing would once again be permitted to assume responsibility for certifying all of its 737 Max and 787 aircraft.
The latest directive does not indicate any confirmed cracking in the affected Max aircraft. However, it reflects the regulator's effort to identify potential structural issues before they develop into operational or safety concerns, reinforcing continued oversight of one of the aviation industry's most closely watched aircraft programmes.
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