
The Federal Aviation Administration has issued an airworthiness directive requiring operators of Boeing 737 Max aircraft to conduct inspections for possible cracks in fuselage components known as bear straps. These structural elements support the fuselage around emergency exit doors. The order affects an estimated 471 aircraft and mandates inspections beginning in September.
The FAA stated that while no cracks have yet been discovered in 737 Max models, the aircraft’s similar design and manufacturing process to earlier Boeing 737 Next Generation planes makes it susceptible to developing such defects. The agency warned that without preventive action, structural integrity could be compromised, potentially affecting the aircraft’s ability to withstand critical loads during operation. The directive follows a comparable inspection regime for the preceding 737 Next Generation model that began in 2021, when cracks in the same components were identified on those planes.
Boeing indicated it has been coordinating with airlines operating 737 aircraft for several years following the company’s initial identification of the issue in 2019. A Boeing spokesperson stated the company supports both the new directive and the earlier inspection mandate for the 737 Next Generation. The aircraft manufacturer noted that the inspection process would provide multiple opportunities to identify and address problems before cracks reach critical dimensions, and that engineering modifications are underway to address root causes.
The directive reflects heightened scrutiny of Boeing’s engineering and manufacturing standards. The 737 Max model faced significant challenges following its entry into service, with design flaws implicated in fatal crashes that occurred in 2018 and 2019, leading to a worldwide grounding. More recently, a panel failure incident on a 737 Max operated by Alaska Airlines in 2024 renewed concerns about production quality, prompting measures such as Ryanair deploying engineers to oversee Boeing’s manufacturing processes.
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