FAA Orders Boeing 757 Precooler Inspections to Prevent Engine Overheating
Published Date: 12/9/2025
Rule
Summary
The FAA is making sure certain Boeing 757 airplanes stay safe by requiring checks and fixes for worn-out parts that could cause overheating. Starting January 13, 2026, airlines must inspect engine parts, test thermal switches, and replace precoolers on some 757-300 models. These steps help prevent engine damage and keep flights safe, with costs depending on the work needed.
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
Estimated Compliance Costs to U.S. Operators
The FAA estimates the AD affects 235 U.S.-registered airplanes. Estimated costs include: $1,020 per airplane for the inspection (12 work-hours at $85/hour; total $239,700 for U.S. operators), $1,700 per airplane per temperature/continuity test cycle (20 work-hours; total $399,500 per test cycle), and for 21 Model 757-300 airplanes precooler replacement costs up to $99,565 per replacement (34 work-hours plus up to $96,675 parts; total up to $2,090,865). On-condition actions include a strut overheat detection system test at $170, and thermal switch replacements with cost-per-product examples of $1,109, $1,874, and $3,980 depending on part number.
Required Inspections, Tests, and Fixes
Starting January 13, 2026, operators of certain Boeing Model 757 airplanes must inspect the engine strut structure for heat damage, perform repetitive thermal switch temperature tests and ground-wire continuity tests, and perform applicable on-condition repairs. The AD specifically requires replacement of the precooler on some Model 757-300 airplanes and follows Boeing Alert Requirements Bulletin 757-26A0062 RB, dated January 17, 2025.
Precooler Replacement Interval Set
For Model 757-300 airplanes, the AD requires replacement of the precooler at intervals not to exceed 45,000 total precooler flight hours. This replacement interval is specified in Boeing Alert Requirements Bulletin 757-26A0062 RB, dated January 17, 2025, and is required as of January 13, 2026.
Safety Risk Reduction for Air Travel
The AD targets precooler wear and latently failed overheat detection thermal switches to prevent prolonged high-temperature exposure of the engine strut. The FAA states the unsafe condition could lead to separation of the engine strut-to-wing box connection; the AD’s inspections, tests, and replacements are intended to address that risk as of January 13, 2026.
Your PRIA Score
Personalized for You
How does this regulation affect your finances?
Sign up for a PRIA Policy Scan to see your personalized alignment score for this federal register document and every other regulation we track. We analyze your financial profile against policy provisions to show you exactly what matters to your wallet.
Key Dates
Department and Agencies
Related Federal Register Documents
2026-08943 — Designation-Restrict the Operation of Unmanned Aircraft in Close Proximity to a Fixed Site Facility
The FAA is proposing new rules to keep drones away from certain important fixed sites like power plants or airports to keep everyone safe and secure. If you own or operate one of these sites, you can request a drone flight restriction zone to protect your property and people nearby. Comments are open until July 6, 2026, and these changes could affect drone pilots and site operators, but no big costs are expected.
2026-10293 — Prohibition of Remote Dispatching
The FAA wants to stop airplane dispatchers from working remotely, except in emergencies when the main center is down. This change affects all domestic, flag, and supplemental airline operators and aims to keep flight safety tight and clear. Comments on this rule are open until July 21, 2026, so airlines and dispatchers should get ready for a new way of working that could shake up their routines.
2026-10270 — Airworthiness Directives; Embraer S.A. (Type Certificate Previously Held by Yaborã Indústria Aeronáutica S.A.; Embraer S.A.) Airplanes
The FAA is requiring certain Embraer ERJ 190-100 ECJ airplanes to get a close check on their overheat detection sensors because some parts might not work right. If problems are found, those parts must be replaced, and no faulty parts can be installed anymore. This rule kicks in on June 26, 2026, helping keep flights safe without breaking the bank.
2026-10256 — Airworthiness Directives; Airbus Helicopters
If you fly Airbus EC130T2 helicopters, the FAA wants you to install a new fix on the tail rotor drive shaft and keep checking its vibration regularly. This update replaces old rules and stops certain parts from being used unless they meet new safety standards. You’ve got until July 6, 2026, to share your thoughts, and while this might cost some bucks, it’s all about keeping flights safe and smooth.
2026-10271 — Airworthiness Directives; Bombardier, Inc., Airplanes
The FAA is making sure certain Bombardier BD-700 airplanes are safe by checking and fixing bolts on the baggage door that might have been tightened wrong. Owners need to inspect and adjust or replace these bolts by June 26, 2026, to keep flying safely. This fix helps avoid any door problems and keeps passengers secure without breaking the bank.
2026-10272 — Airworthiness Directives; Airbus SAS Airplanes
If you fly or work with Airbus A330 planes, listen up! The FAA found a problem where a backup fuel pump might fail quietly, trapping fuel that can’t be used. Starting June 8, 2026, airlines must regularly check these pumps and fix any issues to keep flights safe—no big wallet hits expected, just smart safety moves.
Previous / Next Documents
Previous: 2025-22339 — Airworthiness Directives; ATR-GIE Avions de Transport Régional Airplanes
If you fly or work with ATR42 or ATR72 airplanes, listen up! The FAA says these planes need more frequent checks on a key valve to keep everyone safe because it might fail if left unchecked. Starting January 13, 2026, these tests must happen regularly, which could mean some extra time and money but keeps the skies safer.
Next: 2025-22346 — Airworthiness Directives; ATR-GIE Avions de Transport Régional Airplanes
The FAA is making sure certain ATR airplanes get a safety check because a fire extinguisher tube was found disconnected in the cargo area. Starting January 13, 2026, affected planes must have their fire extinguishing systems tested and fixed if needed to keep everyone safe. This update mainly affects ATR42 and ATR72 models and helps prevent fire risks without big costs or downtime.