FAA Orders Crack Checks on Vintage Boeing 737s Nationwide
Published Date: 2/10/2025
Rule
Summary
If you own or operate Boeing 737 models 100 through 500, listen up! The FAA found cracks in a key part of the plane’s frame and now requires inspections and repairs to keep flights safe. Starting March 17, 2025, these checks must happen regularly, helping prevent costly problems and keeping passengers secure.
Analyzed Economic Effects
5 provisions identified: 2 benefits, 3 costs, 0 mixed.
Mandatory inspections and repairs for 737-100/-500
If you own or operate Boeing Model 737-100, -200, -200C, -300, -400, or -500 airplanes, you must inspect the frame inner chord and web at station (STA) 727 for any repair and for cracking, and perform applicable on-condition repairs. The AD requiring these inspections and repairs is effective March 17, 2025.
AD prevents possible structural failure
The FAA found cracks in the left and right frames at STA 727 that could grow to a critical length and cause a principal structural element to be unable to sustain limit load. The AD requires inspections and on-condition actions to detect and address those cracks before they reach a critical length.
FAA cost estimate: 245 planes; $680 inspection
The FAA estimates the AD affects 245 U.S.-registered airplanes. The estimated cost per inspection is 8 work-hours × $85/hour = $680 per airplane (parts $0), for a total estimated cost to U.S. operators of $166,600. The FAA has no definitive cost estimate for on-condition repair actions.
120‑day initial inspection deadline for Group 1
For airplanes identified as Group 1 in Boeing Alert Requirements Bulletin 737-53A1416 RB (dated July 21, 2023), you must inspect for existing repairs and cracking at STA 727 within 120 days after the AD's effective date (March 17, 2025).
Winglet STC does not change compliance
If your airplane has Supplemental Type Certificate STC ST01219SE (winglets), that installation does not affect your ability to perform the AD actions, and you do not need a 'change in product' alternative method of compliance (AMOC) approval to comply with 14 CFR 39.17.
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