The Federal Aviation Administration issued an airworthiness directive requiring operators of Boeing 737 Max aircraft to inspect their fuselages for possible cracks in structural components. The directive will apply to an estimated 471 planes and marks an extension of inspection protocols previously implemented for older Boeing models.
The focus of the inspections centers on components known as bear straps, which are structural sheets that support the fuselage around exit doors. Cracks in these components were previously identified in Boeing 737 Next Generation aircraft, leading the FAA to initiate similar inspection programs beginning in 2021. Although no cracks have been detected in 737 Max aircraft to date, the regulator determined that the model’s comparable design and manufacturing processes create a potential vulnerability to such defects.
According to FAA statements, unaddressed cracks could compromise the ability of primary structural elements to withstand maximum operational loads and potentially undermine overall aircraft structural integrity. Boeing stated it had been coordinating with airlines operating 737 aircraft since identifying the issue in 2019. The company indicated support for the FAA directive and noted that inspections would provide multiple opportunities to detect and address problems before cracks reach critical dimensions. Boeing also reported ongoing work on engineering modifications to prevent the root cause of such cracking.
The directive underscores continued scrutiny of Boeing’s aircraft following significant operational challenges with the 737 Max. The model experienced two fatal crashes in 2018 and 2019 before being grounded globally, resulting in hundreds of fatalities. More recently, a panel separation incident occurred on a 737 Max operated by Alaska Airlines during flight in 2024. These issues prompted major customers, including Ryanair, to deploy additional oversight personnel to Boeing manufacturing facilities to monitor aircraft production and delivery processes.
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