Boeing 737s Need Faster Skin Scans, FAA Orders
Published Date: 3/18/2025
Rule
Summary
If you own or operate certain Boeing 737-800 airplanes, the FAA wants you to speed up a special ultrasonic check on the airplane’s skin under the drag link assembly. This new rule kicks in April 22, 2025, to keep flights safe by catching issues earlier than before. While it might cost some time and money, it’s all about making sure these planes stay rock-solid in the sky.
Analyzed Economic Effects
5 provisions identified: 0 benefits, 5 costs, 0 mixed.
Earlier ultrasonic skin inspection required
For affected airplanes of certain Group/Configuration types, you must perform an ultrasonic inspection of the skin under the drag link assembly by the latest of these times: before 17,000 total flight cycles; within 5,000 flight cycles after July 17, 2019; within 12 months after April 22, 2025; or within 1,000 flight cycles after April 22, 2025. If cracks are found, you must do required on-condition actions and repairs using an FAA‑approved method.
Ultrasonic inspection of repair tripler required
For another set of affected Group/Configuration types, you must perform an ultrasonic inspection of the repair tripler under the drag link assembly by the latest of these times: before 30,000 total flight cycles; within 5,000 flight cycles after July 17, 2019; within 12 months after April 22, 2025; or within 1,000 flight cycles after April 22, 2025. Any on-condition actions discovered by that inspection must be done with FAA-approved repair methods.
Estimated inspection cost per airplane and fleet
The FAA estimates the initial ultrasonic inspection will take up to 23 work-hours at $85 per hour, costing up to $1,955 per airplane. The FAA estimates this AD affects 18 U.S.-registered airplanes, for a total estimated cost to U.S. operators of up to $35,190.
Estimated cost for on‑condition repairs
If inspections find issues, the FAA estimates on-condition actions could take up to 56 work‑hours (up to $4,760 labor) plus up to $24,020 in parts, for a total of up to $28,780 per airplane. The agency did not determine how many airplanes will require these on-condition actions.
Which 737‑800s must comply
This rule applies to Boeing Model 737-800 airplanes that were converted to a freighter using Boeing Drawing 800A0003 before April 1, 2021 and are listed as Group A in Section 5.2.1 of Boeing 737-800BCF Airworthiness Limitations D140A006, Revision L, dated April 1, 2021. If your airplane meets that description, you must follow the inspections and actions in this AD.
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