Boeing 757s Face Cargo Door Hinge Crack Inspections
Published Date: 2/10/2025
Rule
Summary
The FAA is making new safety rules for certain Boeing 757-200 airplanes after cracks were found near the main cargo door hinges. Airlines must check maintenance records, inspect for cracks regularly, and fix any problems to keep flights safe. These rules start on March 17, 2025, and could mean some extra maintenance costs but will help prevent bigger issues down the line.
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
Mandatory inspections and repairs for 757 freighters
If you operate certain Boeing 757-200, -200CB, or -200PF airplanes, you must perform a maintenance record check, repetitive open-hole high frequency eddy current (HFEC) inspections, and corrective actions as required by the AD. The AD affects 564 U.S.-registered airplanes and is effective March 17, 2025; the FAA estimates the maintenance record check is 1 work-hour ($85) per airplane and each HFEC inspection is 26 work-hours ($2,210) per airplane per inspection cycle.
Improves safety by finding cargo-door cracks
The AD is intended to find and fix cracks at the main deck cargo door forward and aft hinge attachment holes to prevent reduced structural integrity of Boeing 757-200 series airplanes. The rule requires inspections and corrective actions to address an unsafe condition and is effective March 17, 2025.
30‑day action for VT MAE converted airplanes
If your airplane was converted to a freighter using VT Mobile Aerospace Engineering (VT MAE) STC ST03562AT, ST03952AT, or ST04242AT, you must obtain FAA-approved inspection instructions and applicable repair instructions within 30 days after March 17, 2025 and then comply with the instructions at the times they specify.
Required inspection intervals for Group 2 airplanes
For Group 2 airplanes addressed by Boeing Alert Requirements Bulletin 757-53A0106 RB, the initial compliance times referenced include either 27,500 flight cycles from the freighter conversion date or 2,800 flight cycles after the AD's effective date, and repetitive inspections at intervals not to exceed 7,000 flight cycles.
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