FAA orders inspections of more than 470 Boeing 737 Max jets over door crack concerns

The US Federal Aviation Administration (FAA) has directed operators of Boeing 737 Max aircraft to inspect for cracks in a component that could jeopardize the structural integrity of the planes. The regulator estimates the directive will cover 471 jets manufactured by Boeing, the US company. The regulation highlights an "unsafe condition" potentially developing on identified products, according to the FAA.

The directive follows reports of cracks near the upper corner of the aircraft's forward galley door, which could spread to the fuselage and affect the "ability of the principal structural element to sustain limit loads," potentially compromising the plane's safety. The directive is set to take effect on September 10, 2026. The checks apply to new-generation Max aircraft, including the 737-8, 737-9, and 737-8200 models currently in service.

Boeing has been collaborating with airlines to address the issue over the past six years, as per Bloomberg. The FAA-mandated inspections are a continuation of similar checks conducted for older-generation 737NG jets in 2021. Boeing has already performed an engineering analysis and is working on changes to prevent future cracking.

This move follows a couple of weeks after the FAA announced that seats on hundreds of Boeing 737 Max aircraft registered in the US may need to be inspected to verify if they were incorrectly installed and require repairs. There are approximately 2,300 Boeing 737 Max aircraft in service globally, including 823 in the US, according to aviation intelligence firm IBA.

The latest directive comes as Boeing aims to enhance manufacturing quality and boost production under chief executive Kelly Ortberg, amid intensified regulatory scrutiny. The company's production challenges were highlighted in early 2024 when a door plug detached from a relatively new Alaska Airlines 737 Max during a flight.