FAA Orders Mandatory Inspections of 471 Boeing 737 MAX Jets Over Structural Cracks

The Federal Aviation Administration has issued a new airworthiness directive requiring inspections of an estimated 471 U.S.-registered Boeing 737 MAX aircraft after cracks were found in a key structural reinforcement component that could compromise the plane’s integrity if left undetected.

The order, published Thursday and effective September 10, 2026, applies to certain Boeing 737-8, 737-9, and 737-8200 models. It was prompted by reports of cracks in the “bear strap,” a structural reinforcement at the forward upper corner of the forward galley door cutout, located around the forward service door on the right side of the aircraft near the front galley.

The FAA warned that undetected cracks in the fuselage skin and bear strap could prevent a principal structural element from sustaining limit loads, potentially affecting the airplane’s overall structural integrity. Airlines must inspect the area on a schedule tied to each aircraft’s flight cycles and repair any cracking before returning the plane to service. Compliance times range from about 3,000 to 30,000 flight cycles depending on the airplane.

Importantly, the FAA has not grounded the fleet. Officials stated that the required inspection intervals provide multiple opportunities to detect and address cracks before they reach a critical length.

Boeing noted that the issue was first identified on older 737 Next Generation (NG) aircraft in 2019 and that the FAA mandated inspections for those models in 2021. The problem has not been observed on the 737 MAX fleet, but the company extended recommended inspections to MAX airplanes because they share a similar design and manufacturing process. Boeing said it has conducted engineering analysis, supports the directive, and is introducing manufacturing process changes to address the root cause on newly built aircraft.

The directive affects approximately 471 jets in the United States and around 1,429 worldwide. It follows a notice of proposed rulemaking issued in late 2025.

This is the latest regulatory action involving the 737 MAX as Boeing continues to address quality and structural issues under heightened FAA oversight.