Boeing 737 Max operators told to check fuselages for cracks

The US Federal Aviation Administration has mandated inspections of the fuselages of Boeing 737 Max aircraft for possible cracks in a component. This directive will affect approximately 471 planes, following reports of cracks in earlier Boeing models. The inspections are set to commence in September.

The concern stems from a component known as the bear strap – sheets that support the fuselage around the exit doors – on the older Boeing 737 Next Generation models. Reports of cracks in these components prompted similar inspections for the 737 Next Generation models in 2021. However, as of now, no such cracks have been identified in the 737 Max aircraft.

The FAA attributes the potential for these cracks to the similar design and build process of the models. They caution that without addressing the issue, it could result in a principal structural element being unable to withstand limit loads, thereby compromising the structural integrity of the aircraft.

Boeing has been collaborating with airlines operating 737s, first identifying and notifying them about the issue in 2019. The company supports both the FAA airworthiness directive and continues to assist its airline customers. Boeing emphasizes that the inspections provide multiple chances to detect and rectify problems before any cracks reach a critical length. They are actively working on engineering changes to address the root cause of the issue.

The focus on engineering problems on Boeing aircraft has grown more pronounced since the problematic entry into service of the 737 Max model. Flaws in this model led to the deaths of hundreds of passengers in two crashes in 2018 and 2019 before it was grounded globally. In 2024, a panel detached from a 737 Max during flight for an Alaska Airlines flight, underscoring ongoing concerns about production issues, which led to Ryanair, the largest customer for the model, sending engineers to Boeing's US factories to oversee the delivery of the planes it had ordered.