FAA Orders Inspections of Boeing 737 Max Jets Over Structural Cracks

The Federal Aviation Administration (FAA) has issued an airworthiness directive that requires airlines to inspect the forward-service-door reinforcement on hundreds of Boeing 737 Max aircraft for cracks that could compromise structural integrity. The directive applies to an estimated 471 U.S.-registered 737 Max 8, Max 9 and Max 8-200 airplanes. Inspections must follow a schedule based on each airplane’s usage, and any detected cracking must be repaired before the aircraft returns to service. The directive takes effect on September 10.

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The directive follows heightened scrutiny of the 737 Max program after a door plug detached from an Alaska Airlines jet in January 2024. The National Transportation Safety Board (NTSB) determined that four bolts intended to secure the plug were missing when the aircraft was delivered in October 2023. Earlier in the same month, the FAA had proposed a separate directive to inspect seat-assembly installations on 453 Max jets, citing concerns about possible mis-installation.

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• 471 U.S.-registered 737 Max aircraft subject to the crack-inspection directive.

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• Aircraft models covered: Max 8, Max 9, Max 8-200.

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• The previously proposed seat-assembly directive would affect 453 Max jets.

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The FAA emphasized that the new inspection intervals provide multiple opportunities to detect cracks before they could affect the aircraft’s structural integrity, and it did not order any grounding of the fleet. Boeing has reportedly altered its manufacturing process to address the reinforcement issue on newly built airplanes. CNN contacted Boeing for comment, but the company did not respond at the time of reporting.

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The FAA’s directive aims to prevent undetected damage from leading to in-flight failures, reinforcing confidence in the Max fleet after a series of high-profile incidents. By mandating inspections tied to aircraft usage, the agency seeks to catch cracks early while allowing airlines to keep planes in service, provided repairs are completed promptly. The measure underscores ongoing regulatory vigilance over Boeing’s production practices and the broader effort to ensure the long-term airworthiness of the 737 Max series.

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