FAA Orders Inspections of 471 Boeing 737 Max Jets for Cracks

The FAA on Thursday ordered fuselage inspections on 471 Boeing 737 Max jets in the U.S. after cracks were found in structural reinforcement around doorways on older 737 models, a defect that could compromise aircraft integrity if left undetected.

"The FAA determined that the directive's required actions and compliance times provide an acceptable level of safety," the agency said in the order published in the Federal Register on Thursday.

The directive, effective Sept. 10, applies to 737-8, 737-9, and 737-8200 models and covers 1,429 aircraft worldwide. Inspections target the bear strap — the structural reinforcement around doorways and emergency exits — and the fuselage skin near the forward service door on the right side of the aircraft. Boeing shares fell 3.33 percent Thursday as investors weighed the cost of mandatory checks and potential repairs.

The order extends to the 737 Max a defect first identified on the older 737 Next Generation fleet, where cracks developed near galley door cutouts under the stress of repeated takeoffs and landings. Boeing said no cracks have been observed on the 737 Max fleet, but the model shares a similar design and build process with the 737NG, prompting the precautionary mandate.

Boeing first notified operators of the 737NG issue in 2019 with detailed inspection instructions, and the FAA mandated those checks in a 2021 airworthiness directive. The company extended inspections to the 737 Max in 2024. The FAA first proposed the current rule in November 2025, which Boeing supported without change.

The directive arrives as regulators maintain heightened scrutiny of Boeing following the January 2024 Alaska Airlines incident, when a door plug blew off a 737 Max 9 at 14,830 feet. The FAA subsequently capped Boeing's 737 Max production rate, a limit the agency slightly increased in October 2025.

Southwest Airlines, one of the largest 737 operators in the U.S., said it was reviewing the directive and would complete inspections on affected aircraft according to the FAA's schedule. United Airlines said it does not anticipate near-term operational impact and will perform inspections during heavy maintenance visits, noting its oldest Max aircraft have not yet reached the flight-cycle threshold triggering the checks. The inspections will require airlines to check the bear strap and surrounding fuselage skin for cracks, a process that could ground aircraft for extended periods if significant damage is discovered.

Regulatory Pipeline Widens

The FAA has also proposed a separate directive requiring inspection of seat assemblies on the same 737 Max models after reports of faulty seat installations. That proposal, published July 27, states that seats could dislodge and injure occupants in emergency landing scenarios.

The Foundation for Aviation Safety, in comments on the crack directive, asked what the FAA and Boeing were doing to address the root cause of the defect. The final rule states that Boeing is introducing changes to the manufacturing process to address the structural reason behind the cracking.

For airlines operating the affected aircraft, the inspections add another layer of compliance cost and potential schedule disruption. For Boeing, the directive extends a regulatory overhang that has constrained production and weighed on deliveries since the 2024 door plug incident. The company's stock has been under pressure as investors price in the cost of inspections, potential repairs, and the broader reputational damage from repeated quality issues on the 737 program.

The NTSB in 2025 also recommended that Boeing modify engines on 737 Max planes following two bird strike incidents in 2023, a recommendation Boeing said it supported. The cumulative effect of these directives and recommendations points to a prolonged period of regulatory oversight for the 737 program, with each new mandate adding to the operational and financial burden on Boeing and its airline customers. For the broader aviation sector, the directive shows the FAA's willingness to mandate preventive maintenance across fleets, a stance that could raise operating costs for carriers that rely heavily on the 737 Max as their primary narrow-body aircraft.

This article is for informational purposes only and does not constitute investment advice.