U.S. — The Federal Aviation Administration issued an airworthiness directive ordering fuselage inspections for certain Boeing 737 Max 8, 737 Max 9, and 737-8200 models. The order was issued after reports of cracks were discovered in the structural reinforcement around the forward service door near the galley on the right side of some older generation Boeing 737 planes.

The directive applies to an estimated 471 planes registered in the U.S. and 1,429 planes worldwide. It takes effect on September 10. So far, no cracks have been found in Boeing 737 Max jets specifically.

The cracks in older planes developed in a component known as the bear strap, which reinforces areas around doorways and emergency exits. The FAA stated that the 737 Max shares a similar design and build process with the Next Generation model, making it susceptible to the same crack condition. The FAA warned that undetected damage could reduce the aircraft’s structural integrity.

Airlines must inspect the area on a schedule based on each airplane’s usage and repair any cracking before returning an affected airplane to service. The FAA did not order the aircraft grounded, stating that the required inspection intervals provide multiple chances to detect cracks before they could compromise the airplane’s structural integrity. The FAA directive requires inspections of the fuselage skin of planes with existing repairs.

Boeing said it first notified operators of its 737 Next Generation planes of the issue in 2019, providing them with detailed instructions for conducting recommended inspections. The requirement follows similar inspections mandated for older-generation Boeing 737 Next Generation (737NG) aircraft in 2021. Boeing said that in 2024 it extended the inspections to 737 Max airplanes because the model shares a similar design and build process to its Next Generation model.

he said it has been aware of the issue and has worked with airline customers for about six years to address it. "We support both directives and continue to support our airline customers," a Boeing spokesperson said. He said it is conducting analysis to determine the root cause of the cracks and prevent them in future aircraft. Boeing has changed its manufacturing process to address the issue on newly built airplanes.

Southwest Airlines said it was reviewing the FAA's airworthiness directive and would accomplish the inspections on the affected airplanes according to the schedule specified by the FAA. "We don't anticipate any impact to our operations in the near term and will accomplish the inspections during heavy maintenance visits," a United Airlines spokesperson said. Akasa Air and Air India Express are two of India's largest operators of Boeing 737 MAX aircraft.

The Federal Aviation Administration is the U.S. government agency regulating civil aviation. This directive connects current Max models to a documented pattern of structural issues in the older Next Generation fleet, requiring proactive maintenance to ensure safety. The scope includes over 1,400 aircraft globally, affecting major operators in the United States and abroad such as those in India. Boeing, established in 1916, continues to analyze the root cause while implementing manufacturing changes for new production.

Why It Matters

This directive links the 737 Max fleet to a documented structural issue in older models, requiring proactive maintenance for over 1,400 aircraft globally to preserve fuselage integrity. Although no cracks have yet been found in Max jets, the shared design necessitates inspections before undetected damage compromises safety. The order mandates repairs prior to return to service but avoids grounding planes by relying on scheduled detection intervals.