FAA Orders Boeing 757 Precooler Inspections to Prevent Engine Overheating
Published Date: 12/9/2025
Rule
Summary
The FAA is making sure certain Boeing 757 airplanes stay safe by requiring checks and fixes for worn-out parts that could cause overheating. Starting January 13, 2026, airlines must inspect engine parts, test thermal switches, and replace precoolers on some 757-300 models. These steps help prevent engine damage and keep flights safe, with costs depending on the work needed.
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
Estimated Compliance Costs to U.S. Operators
The FAA estimates the AD affects 235 U.S.-registered airplanes. Estimated costs include: $1,020 per airplane for the inspection (12 work-hours at $85/hour; total $239,700 for U.S. operators), $1,700 per airplane per temperature/continuity test cycle (20 work-hours; total $399,500 per test cycle), and for 21 Model 757-300 airplanes precooler replacement costs up to $99,565 per replacement (34 work-hours plus up to $96,675 parts; total up to $2,090,865). On-condition actions include a strut overheat detection system test at $170, and thermal switch replacements with cost-per-product examples of $1,109, $1,874, and $3,980 depending on part number.
Required Inspections, Tests, and Fixes
Starting January 13, 2026, operators of certain Boeing Model 757 airplanes must inspect the engine strut structure for heat damage, perform repetitive thermal switch temperature tests and ground-wire continuity tests, and perform applicable on-condition repairs. The AD specifically requires replacement of the precooler on some Model 757-300 airplanes and follows Boeing Alert Requirements Bulletin 757-26A0062 RB, dated January 17, 2025.
Precooler Replacement Interval Set
For Model 757-300 airplanes, the AD requires replacement of the precooler at intervals not to exceed 45,000 total precooler flight hours. This replacement interval is specified in Boeing Alert Requirements Bulletin 757-26A0062 RB, dated January 17, 2025, and is required as of January 13, 2026.
Safety Risk Reduction for Air Travel
The AD targets precooler wear and latently failed overheat detection thermal switches to prevent prolonged high-temperature exposure of the engine strut. The FAA states the unsafe condition could lead to separation of the engine strut-to-wing box connection; the AD’s inspections, tests, and replacements are intended to address that risk as of January 13, 2026.
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