WASHINGTON—The U.S. Federal Aviation Administration on Friday ordered inspections of hundreds of Boeing 737 MAX aircraft after determining they should be checked for possible structural cracks in a fuselage reinforcement component, expanding precautionary oversight following similar issues previously identified on older-generation 737 aircraft.
The FAA issued an airworthiness directive requiring inspections of 471 U.S.-registered Boeing 737 MAX 8, MAX 9 and 737-8200 aircraft. The agency said the inspections are intended to detect potential cracking in the "bear strap," a structural reinforcement located near the forward service door, even though no such cracks have been found on 737 MAX aircraft to date.
According to the FAA, the directive was prompted by cracking previously discovered in comparable structures on Boeing's 737 Next Generation fleet. Because the MAX family uses a similar design and manufacturing approach in the affected area, regulators concluded that inspections are necessary to identify any developing fatigue before it could affect structural integrity. The agency said the mandated inspection intervals provide multiple opportunities to identify and repair any cracks before they become a safety concern.
The inspections are scheduled to begin in September under the FAA directive. The agency did not order the aircraft grounded and said operators can continue flying the jets while complying with the required inspection schedule.
Boeing said it supports the FAA's action and has been working with airlines on the issue since 2019. The manufacturer said the inspections are designed to detect any signs of cracking early enough for repairs to be completed before the condition could become critical.
The latest directive comes as Boeing continues to operate under heightened regulatory scrutiny following two fatal 737 MAX crashes in 2018 and 2019 that led to a worldwide grounding of the aircraft, as well as renewed oversight after a door-plug panel detached from an Alaska Airlines 737 MAX 9 during flight in January 2024. Federal investigators later determined that retaining bolts had been missing when that aircraft left Boeing's factory.
In July, the FAA restored Boeing's authority to resume issuing airworthiness certificates for newly built 737 MAX and 787 aircraft after concluding that months of enhanced oversight had demonstrated consistent production quality. The regulator said at the time it would continue inspections, audits and monitoring of Boeing's manufacturing system despite returning part of the certification responsibility to the company.
