The Federal Aviation Administration has issued an airworthiness directive requiring operators of Boeing 737 Max aircraft to inspect fuselages for possible cracks in structural components. The directive is estimated to affect approximately 471 planes and mandates that inspections begin in September.
The directive focuses on a component known as the bear strap, which consists of sheets that provide structural support around exit doors on the fuselage. While cracks have previously been identified in this component on earlier Boeing 737 Next Generation models, the FAA stated that no such cracks have been discovered in 737 Max aircraft to date. However, the agency cited similarities in design and manufacturing processes between the 737 Max and older models as reason for concern that the newer planes could be susceptible to developing the same defects.
According to the FAA, failure to address this issue could compromise the structural integrity of aircraft by preventing principal structural elements from sustaining operational loads. The inspection regime follows a comparable program that has been in place for 737 Next Generation models since 2021.
Boeing indicated it has been coordinating with airlines operating 737 aircraft for several years on this matter, having first alerted operators to the potential issue in 2019. The company stated support for the FAA’s directive and noted that the inspection process would create multiple opportunities to identify and correct problems before any cracks reach critical dimensions. Boeing added that it is actively pursuing engineering solutions to address the underlying cause.
The latest directive reflects ongoing scrutiny of Boeing’s manufacturing and design practices. The 737 Max model faced widespread groundings following crashes in 2018 and 2019, and subsequent incidents including a panel separation on an Alaska Airlines flight in 2024 have continued to draw attention to production quality concerns.
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