The Federal Aviation Administration (FAA) has issued an Emergency Airworthiness Directive requiring immediate inspections of certain Boeing 737 Next Generation (NG) aircraft following the discovery of structural cracks on critical components. The move comes after Boeing notified the FAA about the issue, heightening worries over long-term airframe fatigue in the widely used aircraft.
According to the FAA, the issue involves cracks on a component known as the ‘pickle fork,’ a structure that helps attach the aircraft’s fuselage to the wing. These cracks were identified on aircraft that had not yet reached the threshold for full durability testing—raising red flags about the structural integrity of what was considered a mature and reliable fleet.
Inspections are initially required for 737 NG aircraft that have completed 30,000 or more flight cycles, with Boeing estimating that fewer than 5% of active NG planes are affected. However, the directive states that even planes with lower flight cycles may eventually be included if additional cracks are found.
The FAA clarified that immediate inspections must be completed within seven days for at-risk aircraft. Planes found with cracking must be pulled from service until repairs are completed. The directive affects thousands of aircraft currently in service with major global airlines, including Southwest, American Airlines, and Ryanair, although only a fraction are likely impacted.
This incident marks the latest challenge for Boeing as it continues to recover from safety controversies linked to the 737 Max, a variant of the NG model line. While the affected NG planes are structurally different from the Max, the recurrence of integrity issues has prompted renewed scrutiny from regulators and carriers.
Boeing has stated it is working closely with the FAA and its airline customers to conduct inspections and implement repairs where necessary. “We are committed to ensuring every plane in service meets the highest safety standards,” said a spokesperson for the company.
Aviation analysts say the FAA’s swift action reflects heightened sensitivity to safety concerns, especially after the tragic crashes involving the 737 Max in 2018 and 2019. The agency emphasized that it is erring on the side of caution due to the potential for catastrophic failure if the cracks were left unaddressed.
Airlines around the world are now expediting checks of their 737 NG fleets, with minimal expected disruption to service as substitutes and contingency plans are implemented. The FAA is expected to monitor results of the inspections closely to determine whether further directives or design changes will be necessary.
The Boeing 737 NG family includes the -600, -700, -800, and -900 models, and is one of the most widely flown narrow-body aircraft globally. While considered highly reliable over the past two decades, this incident underscores the mechanical challenges that can emerge as aircraft approach the latter parts of their operational lifespans.
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