FAA orders Boeing 737 Max inspections over potential cracks

The Federal Aviation Administration (FAA) has ordered inspections of hundreds of Boeing 737 Max jets over possible cracking in the aircraft’s body, though Boeing said the issue has not been seen on the Max fleet.

The airworthiness directive (AD) applies to certain Boeing 737 Max 8, Max 9 and Max 8-200 airplanes and affects an estimated 471 U.S.-registered aircraft.

Airline operators must inspect the fuselage skin and carry out additional inspections or repairs when needed.

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“This AD was prompted by reports of cracks in the bear strap at the forward upper corner of the forward galley door cutout,” the directive states. 

“The FAA is issuing this AD to address cracks in the fuselage skin and bear strap, which may lead to the inability of the principal structural element to sustain limit loads and adversely affect the structural integrity of the airplane.”

The Boeing logo is displayed near London July 21, 2026. The FAA has ordered inspections of hundreds of Boeing 737 Max aircraft. (Toby Shepheard/AFP via Getty Images)

The directive takes effect Sept. 10, 2026.

Boeing told FOX Business the issue was first identified on certain 737 Next Generation aircraft and has not been seen on the 737 Max fleet.

The company said it extended the inspections to Max aircraft because the models share a similar design and manufacturing process.

“Boeing identified and reported this issue and has been working with operators on it over the past six years,” the company said.

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Boeing 737 Max aircraft at the company’s factory in Renton, Wash., April 15, 2026. The directive takes effect Sept. 10, 2026. (M. Scott Brauer/Bloomberg via Getty Images)

Boeing notified 737 Next Generation operators about the issue in 2019, and the FAA mandated inspections for those aircraft in 2021.

“The FAA airworthiness directive published today mandates the inspections, as it did for the 737 Next Generation. We support both directives and continue to support our airline customers,” Boeing said.

The aircraft manufacturer said the inspections provide multiple opportunities to detect and correct possible cracks before they exceed a critical length.

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Boeing has also conducted an engineering analysis to determine the root cause and is implementing manufacturing changes. (Mario Tama/Getty Images)

Boeing has also conducted an engineering analysis to determine the root cause and is making manufacturing changes intended to prevent the condition.

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“Boeing is introducing changes to the manufacturing process that address the root cause of the unsafe condition on in-production airplanes,” the FAA directive noted.