- The FAA ordered inspections of 471 Boeing 737 MAX planes for potential structural cracks
- The directive applies to 737-8, 737-9, and 737-8200 models starting September 10, 2026
- No cracks found yet on 737 MAX; concerns arise from older 737 NG aircraft cracks
The US Federal Aviation Administration has ordered inspections of 471 Boeing 737 MAX aircraft after concerns over potential structural cracks in an area of the fuselage near the forward galley door, according to a report.
The directive covers the 737-8, 737-9 and 737-8200 models and takes effect on September 10, 2026, the Associated Press reported.
Importantly, no cracks have so far been reported on the affected 737 MAX models themselves. The FAA's action follows reports of cracking on older Boeing 737 Next Generation aircraft that use a similar design and manufacturing process. The regulator has determined that the MAX aircraft could therefore be susceptible to the same condition, according to AP.
The inspections focus on the bear strap, a metal structural reinforcement around openings such as doors, at the forward upper corner of the forward galley door cutout.
The FAA's concern stems from cracks previously found in the bear strap and surrounding structure on 737-600, 737-700, 737-700C, 737-800, 737-900 and 737-900ER aircraft. Boeing's investigation linked those cracks to high operating stresses in the fuselage skin and bear strap caused by stress concentration around the door opening.
If such cracking develops and remains undetected, it could affect the ability of a key structural component to withstand required loads and compromise the aircraft's structural integrity, according to the FAA.
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The new directive requires operators to inspect the relevant fuselage areas and address any cracks or existing repairs as specified by Boeing's inspection procedures. The checks include visual inspections and, where required, more detailed inspections using high- and low-frequency eddy-current techniques.
Boeing said it identified the issue previously and has been working with airlines on inspections for around six years. The company provided inspection instructions for affected 737 Next Generation aircraft in 2019, while the FAA mandated inspections for those planes in 2021, the report stated.
Boeing also expanded the inspection process to MAX aircraft and supports the FAA's latest directive.
The latest action adds to the regulatory scrutiny surrounding Boeing's MAX programme. The aircraft family has faced intense safety oversight following the 2018 and 2019 737 MAX crashes, which killed 346 people, and the 2024 Alaska Airlines incident involving a panel that separated from a 737 MAX 9 during flight.
For now, the FAA's directive is a preventive inspection measure rather than a response to confirmed cracks on the affected MAX aircraft. Operators must begin complying with the inspections by September 10.
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