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FAA Orders Inspections of Hundreds of Boeing 737 MAX Over Potential Door‑cutout Cracks

The directive requires recurring targeted inspections to detect cracks in a small reinforcement and nearby fuselage skin that could weaken the forward service‑door cutout.

Overview

  • The FAA issued the airworthiness directive on August 7, 2026 and made Boeing’s December 2024 Alert Requirements Bulletin mandatory for U.S. operators, with the rule taking effect on September 10, 2026.
  • The AD covers specified 737 MAX 8, 8‑200 and 9 jets and directs recurring detailed inspections plus high‑ and low‑frequency eddy‑current tests of the Bear Strap and adjacent fuselage skin near the forward service‑door cutout.
  • The Bear Strap is a small reinforcement plate at the upper front corner of the service‑door opening and cracks there can spread into load‑carrying structure and harm the airplane’s structural integrity.
  • The AD requires operators to follow Boeing’s bulletin for exact inspection intervals and repair procedures because the FAA rule references the bulletin rather than listing those specifics itself.
  • Boeing says it will change production processes to fix the identified root cause for jets still being built, and the short‑term operational effect will depend on how many aircraft need repairs after inspections.