FAA orders checks on 471 Boeing 737 Max jets over potential crack risk

Chicago,UPDATED: Aug 7, 2026 21:56 IST

The US Federal Aviation Administration has ordered inspections for hundreds of Boeing 737 Max planes after reports of cracks in some older 737 models. The rule was finalised this week, unveiled on Thursday, and will take effect on September 10.

The directive applies to certain Boeing 737-8, 737-9 and 737-8200 aircraft, covering an estimated 471 planes. The FAA said it is issuing the order to address “the unsafe condition” linked to earlier reports, although no cracks have so far been found in these specific Max models.

When the rule was proposed in November, the FAA said it had received reports of cracks in a forward bear strap in several older, Next-Generation 737 planes. Bear straps are metal sheets that reinforce sections of an aircraft such as doorways and emergency exits.

The FAA said the Max jets have “a similar design and build process” to the older models, “making those airplanes susceptible to the same crack condition”. It warned that the issue could “adversely affect the structural integrity of the airplane” if it is not addressed.

In a statement, Boeing said it had previously identified and reported the issue and “has been working with operators on it over the past six years”. The company said it sent inspection instructions for the affected Next-Generation 737s in 2019, and the FAA later made those checks mandatory in 2021.

Boeing added that it had already expanded those inspections to Max jets, and that the FAA’s latest directive now makes that process mandatory as well. “We support both directives and continue to support our airline customers,” the company said.

The FAA also said on Thursday that its directive requires inspections of the fuselage skin of planes that already have repairs in place.

Boeing has faced years of safety, quality and production problems, including the aftermath of two deadly 737 Max crashes in 2018 and 2019 that killed 346 people, and a 2024 incident in which a panel flew off an Alaska Airlines-operated Max 9 plane mid-flight. Last month, the FAA said Boeing would again be allowed to take responsibility for certifying all of its 737 Max and 787 planes. Overall, the new order extends inspection requirements to certain Max aircraft as the FAA moves to address a potential structural risk linked to cracks seen in older 737s.

With PTI Inputs

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