Boeing 767 Wings Get Crack-Check Mandate Proposal
Published Date: 4/10/2025
Proposed Rule
Summary
The FAA wants Boeing 767 airplanes checked for cracks near key wing parts after finding a problem with a fastener hole. They’re proposing special inspections and fixes to keep these planes safe. Owners need to comment by May 27, 2025, and be ready for inspections that might cost some time and money but keep flights safe and sound.
Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Mandatory HFEC inspections for Boeing 767s
If you operate a Boeing 767-200, -300, -300F, or -400ER, the FAA would require an open-hole high frequency eddy current (HFEC) inspection of fastener holes common to the underwing longeron (UWL) fitting, upper drag splice angle, and lower drag splice angle. The FAA estimates the inspection takes 170 work-hours at $85/hour ($14,450 per airplane) and would affect 600 U.S.-registered airplanes, for a total estimated cost to U.S. operators of $8,670,000. Comments on the proposal are due by May 27, 2025.
Potential repair costs if cracks found
If the inspection finds cracks, required on-condition actions include repairs or replacement that can cost up to $16,885 for replacement (19 work-hours at $85/hr = $1,615 labor plus $15,270 parts). Additional follow-up inspections can cost up to $14,450 each, and smaller inspections/repairs are estimated up to $510. The FAA did not estimate how many airplanes will require these on-condition actions.
Risk of structural failure if not repaired
The FAA found a fatigue crack 0.30 inch long and 0.37 inch deep in a UWL fitting on a Boeing 767 that had 80,955 flight hours and 22,620 flight cycles. The rule says an unrepaired crack could lead to loss of the primary load path between the fuselage and the wing box, which would adversely affect the airplane's structural integrity. Requiring inspections and repairs is intended to prevent that unsafe condition.
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