FAA Mandates Crack Inspections on 471 Boeing 737 Max Jets

The Federal Aviation Administration (FAA) has finalized a directive requiring structural inspections on a significant portion of Boeing's 737 Max fleet. The rule, announced Thursday and effective September 10, applies to the 737-8, 737-9, and 737-8200 models, covering an estimated 471 aircraft in total.

The order stems from concerns about potential cracking in a component known as a forward bear strap, a metal reinforcement used around doorways and emergency exits. While no cracks have been discovered on the Max jets themselves, the FAA noted in its November proposal that similar issues had been reported on older "Next-Generation" 737 aircraft. Because the Max series shares a similar design and build process, the agency concluded the newer planes could be susceptible to the same condition, which it warned could compromise structural integrity if left unaddressed.

Boeing responded by stating it had already identified the issue and has been collaborating with operators for the past six years. The company said it provided inspection instructions for the older 737s in 2019, a process the FAA mandated in 2021. Boeing added that it had already extended these checks to the Max fleet, and the new FAA directive now makes that process a formal requirement. The company expressed support for the directive and reaffirmed its commitment to assisting airline customers.

The FAA's latest rule also mandates checks of the fuselage skin on planes that have undergone prior repairs. This action adds to the ongoing regulatory scrutiny Boeing has faced following a series of safety and production challenges, including two fatal crashes involving the Max 8 in 2018 and 2019, and a mid-flight panel incident on a Max 9 in 2024. Just last month, the FAA restored Boeing's authority to certify its own 737 Max and 787 aircraft, a step in the company's broader recovery efforts.