The US Federal Aviation Administration (FAA) has ordered inspections of the fuselages of hundreds of Boeing 737 Max aircraft after cracks were identified in a structural component on older versions of the 737.
The directive, which takes effect on September 10, covers an estimated 471 aircraft across three variants: the Boeing 737-8, 737-9 and 737-8200. The inspections will focus on the forward bear strap, a metal component that reinforces the fuselage around passenger doors and emergency exits.
The FAA said no cracks have so far been detected in the affected 737 Max models. However, the agency determined that the aircraft share a similar design and manufacturing process with older 737 Next Generation aircraft where cracks have previously been reported, making them potentially susceptible to the same problem.
The regulator warned that if the issue is not identified and addressed, it could affect the ability of a key structural component to withstand required loads and potentially compromise the structural integrity of the aircraft.
The latest directive follows inspections ordered for Boeing 737 Next Generation aircraft after reports of cracks in their bear straps. Boeing first identified the issue in 2019 and provided inspection guidance to operators, before the FAA formally mandated inspections of the older aircraft in 2021.
Under the new directive, operators of affected 737 Max aircraft will be required to inspect the relevant fuselage areas and, in some cases, the fuselage skin around existing repairs.
Boeing said it supports the FAA directive and has been working with airlines on the issue for several years. The manufacturer said the inspections would provide opportunities to detect and repair potential cracks before they reach critical lengths, while engineering work continues to address the underlying cause.
The directive comes as Boeing remains under heightened regulatory and industry scrutiny over the safety and quality of its commercial aircraft.
The 737 Max was grounded worldwide following two fatal crashes involving Max 8 aircraft in Indonesia in 2018 and Ethiopia in 2019, which together killed 346 people. The manufacturer faced renewed scrutiny in January 2024 after a door plug detached from an Alaska Airlines 737 Max 9 during a flight, prompting further investigations into Boeing’s production and quality-control processes.
The FAA subsequently increased its oversight of Boeing’s manufacturing operations and certification processes. The latest inspection requirement underscores the regulator’s continued focus on identifying potential structural issues before they develop into more serious safety concerns.
