The Federal Aviation Administration issued an airworthiness directive requiring operators of Boeing 737 Max aircraft to conduct inspections of fuselage components for possible cracks. The directive impacts an estimated 471 planes and mandates inspections beginning in September.
The targeted component is the bear strap, which consists of sheets that support the fuselage structure around emergency exit doors. While no cracks have been detected in 737 Max aircraft to date, the FAA determined that the model’s design and manufacturing process create conditions similar to those found in earlier Boeing 737 Next Generation planes, where such cracks have been documented. The regulator stated that failure to address potential cracking could compromise a critical structural element and reduce the airplane’s ability to withstand maximum operational loads, potentially affecting overall structural integrity.
The inspection mandate follows a precedent established for the 737 Next Generation fleet beginning in 2021. Boeing indicated it had been collaborating with airlines on the matter following an initial identification of the issue in 2019. A Boeing representative confirmed the company supports both the current and previous inspection directives, noting that systematic inspections would provide opportunities to identify and address defects before cracks reach dangerous lengths. The manufacturer stated it is simultaneously pursuing engineering modifications to address the underlying cause.
The order comes amid sustained scrutiny of Boeing’s manufacturing practices. The 737 Max experienced two fatal crashes in 2018 and 2019 due to design defects, resulting in a worldwide grounding of the model. More recently, a panel separation incident occurred on a 737 Max operated by Alaska Airlines in 2024. These issues have prompted increased oversight, with major carriers such as Ryanair deploying engineers to Boeing’s manufacturing facilities to monitor quality control during aircraft delivery.
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