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FAA orders inspection of hundreds of 737 Max jets for cracks

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FILE - A Boeing 737 Max jet prepares to land at Boeing Field following a test flight in Seattle, Sept. 30, 2020. Boeing says its supplier has discovered another problem with fuselages of its 737 jets that might delay deliveries of about 50 aircraft. Both Boeing and Spirit AeroSystems are facing intense scrutiny over the quality of their work after an Alaska Airlines 737 Max 9 was forced to make an emergency landing, Jan. 5, 2024, when a panel called a door plug blew out of the side of the plane shortly after its takeoff from Portland, Ore. (AP Photo/Elaine Thompson, File)

The U.S. Federal Aviation Administration has ordered inspections of hundreds of Boeing 737 Max jets for cracks in the body of the plane, warning that undetected damage could reduce the aircraft’s structural integrity.

The new airworthiness directive applies to an estimated 471 U.S.-registered Boeing 737 Max 8s, Max 9s and Max 8-200 airplanes.

Cracks were found on some planes in a structural reinforcement around the forward service door on the right side of the airplane, next to the front galley, the FAA said.

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.

Boeing has conducted an engineering analysis to determine the cause of the cracks and is working on engineering changes to prevent it in the future, the company said in a statement.

image.jpg-1.21236680 A Boeing 737 MAX 9 model sits outside its production plant, Tuesday, March 7, 2017, in Renton, Wash. (AP Photo/Elaine Thompson)

The FAA did not order the aircraft grounded, saying the required inspection intervals provide multiple chances to detect cracks before they could compromise the airplane’s structural integrity.

The directive takes effect Sept. 10.

This is not the first time the company has had to deal with structural cracking on 737s. In 2019, inspections were ordered for some Boeing 737-700, 737-800, and 737-900 after some planes were found to have cracks in the component connecting the plane’s fuselage to the wings.

“This issue has not been observed on the 737 MAX fleet, but Boeing extended the inspections to 737 MAX airplanes as the model shares a similar design and build process,” the company said in a statement. “We support both directives and continue to support our airline customers.”

am800-news-boeing-737-max-8-getty-1.9007679 RENTON, WA - MARCH 11: A 737 MAX airplane is pictured on he tarmac with its signature winglet and fuel efficient engines outside the company's factory on March 11, 2019 in Renton, Washington. Boeing's stock dropped today after an Ethiopian Airlines flight was the second deadly crash in six months involving the Boeing 737 Max 8, the newest version of its most popular jetliner. (Photo by Stephen Brashear/Getty Images)

Last month, the FAA proposed another airworthiness directive that would require the inspection of seat assemblies on 453 Boeing 737 Max jets in case they were incorrectly installed.

The manufacturer has been under scrutiny since a door plug blew out of an Alaska Airlines jet in January 2024. The National Transportation Safety Board found four bolts that were supposed to hold the door plug in place were missing when the plane was delivered the airline in October 2023.

Pete Muntean, CNN