The U.S. Federal Aviation Administration (FAA) has ordered inspections of hundreds of Boeing 737 MAX aircraft after identifying a potential structural fatigue issue involving a fuselage reinforcement near the forward service door.
The new airworthiness directive applies to 471 U.S.-registered 737 MAX 8, MAX 9 and MAX 8-200 aircraft. It becomes effective on Sept. 10.
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The inspections focus on the upper corners of the right-side forward door frame, where structural reinforcements known as bear straps could develop fatigue cracks. According to the FAA, undetected damage could eventually reduce the airframe's ability to withstand design loads.
No cracks have been reported on 737 MAX aircraft. However, the agency said the type shares the same structural design and manufacturing approach used on earlier 737 generations, where similar cracking has previously been identified.
Operators will be required to inspect the affected area according to schedules based on each aircraft's utilization. Any cracks found must be repaired before the aircraft returns to service.
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Boeing said it has completed an engineering analysis to determine the root cause of the issue and is developing design changes intended to eliminate the cracking mechanism in future aircraft. The manufacturer also noted that it had previously recommended inspections through a service bulletin issued to operators in late 2024.
The FAA did not ground the affected fleet, stating that the inspection intervals were established to provide multiple opportunities to detect and correct any cracks before they become a flight safety concern.
