The Federal Aviation Administration has ordered inspections of approximately 471 Boeing 737 Max aircraft for potential fuselage cracks, with the directive taking effect September 10, 2026, according to an airworthiness directive issued by the regulator on August 7.
The cracks are in a structural component called the “bear strap,” sheets of metal that support the fuselage around the forward exit doors. The FAA said that without action, such cracks could “lead to the inability of a principal structural element to sustain limit loads and adversely affect the structural integrity of the airplane.”
The inspection order covers 737 Max 8, 737 Max 9, and 737-8200 models. Importantly, no cracks have been found on any 737 Max aircraft to date. The FAA issued the directive based on reports of similar cracking discovered on older Boeing 737 Next Generation models, which share comparable design and manufacturing processes with the Max.
Boeing first identified the potential for this issue in 2019 and notified airlines operating 737s, according to the company. A Boeing spokesperson said on August 7 that the company “support[s]” the FAA directive and is “working through engineering changes to tackle the cause.” The inspections, Boeing added, would provide “multiple opportunities to identify and correct problems before any cracks exceed critical length.”
Precedent from Earlier Boeing Models
The FAA implemented a similar inspection regime for the 737 Next Generation beginning in 2021, following the discovery of bear strap cracks on those aircraft. The Guardian reported that the 737 NG cracks were found in the same structural reinforcement around exit doors. The Max directive follows the same pattern, treating the newer model as potentially susceptible to the same wear and stress that affected its predecessor.
The FAA estimates that initial general visual inspections will cost U.S. operators approximately $85 per aircraft, according to reporting from Aviation Pros. Operators will be required to inspect the fuselage skin for existing repairs and perform applicable on-condition actions if cracks are found.
Boeing’s Broader Safety Context
The fuselage crack directive comes as Boeing faces intensified scrutiny over production and engineering issues. In January 2024, a panel blew out of a 737 Max during flight on an Alaska Airlines plane, prompting heightened attention to manufacturing quality. That incident, combined with the 737 Max’s troubled history—the aircraft was grounded worldwide after two fatal crashes in 2018 and 2019 that killed hundreds—has made regulators and airlines more vigilant about structural concerns.
Ryanair, Boeing’s largest customer for the 737 Max, sent its own engineers to Boeing’s U.S. factories to oversee deliveries of planes it had ordered, reflecting industry concern about production standards. The fuselage crack inspections represent another step in the FAA’s ongoing effort to ensure the safety of the 737 Max fleet and prevent structural failures before they occur.
Sources
- The Guardian — FAA airworthiness directive details, bear strap component description, 737 NG precedent, Boeing’s 2019 notification and company statement, 2024 Alaska Airlines panel incident
- AP News — FAA inspection order and affected aircraft count
- Aviation Pros — inspection cost estimate of $85 per aircraft
- Simple Flying — confirmation that no cracks found on 737 Max fleet to date
- Aerospace Global News — directive effective date of September 10, 2026, and affected aircraft models
