FAA Orders Crack Checks on Boeing 757 Fuselages
Published Date: 4/30/2026
Proposed Rule
Summary
The FAA wants all Boeing 757 airplanes checked for cracks in certain repaired parts of the fuselage to keep flights safe. If cracks are found, repairs must be done right away. Owners should act before June 15, 2026, and be ready for inspection costs and possible fixes.
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Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Mandatory 757 Fuselage Inspections
The FAA proposes a rule requiring inspections on all Boeing 757 airplanes for reinforcing repairs in fuselage frame lower lobe areas in sections 43 and 46 (between stringers S-20 and S-25 from STA 440 to STA 820, and between S-25 and S-28 from STA 1300 to STA 1661). The inspections must follow Boeing Alert Requirements Bulletin 757-53A0129 RB, dated December 8, 2025, and include on-condition actions if cracks are found to protect structural integrity.
Estimated Inspection Costs for Operators
The FAA estimates this AD would affect 427 U.S.-registered Boeing 757 airplanes. The inspection is estimated at up to 263 work-hours at $85 per hour, costing up to $22,355 per airplane and up to $9,545,585 across U.S. operators; the FAA has no definitive estimate for additional on-condition repair costs.
Repairs Required Before Further Flight
If the Boeing bulletin specifies contacting Boeing for repair instructions, the proposed AD requires doing the repair and applicable on-condition actions before further flight using an FAA- or approved method. That requirement can cause immediate aircraft downtime until approved repairs are completed.
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