Jet Engines Keep Cracking Mid-Flight, FAA Finally Says 'Check Them'
Published Date: 12/12/2025
Rule
Summary
The FAA is making new rules for certain CFM LEAP engines because cracks were found in important turbine blades after two engines shut down mid-flight. Starting December 29, 2025, these engines need regular inspections and maybe blade replacements to keep flying safely. Airlines and maintenance crews should act fast to avoid costly repairs and keep passengers safe.
Analyzed Economic Effects
3 provisions identified: 0 benefits, 3 costs, 0 mixed.
Mandatory inspections and repairs start Dec 29, 2025
If you operate airplanes with the listed CFM LEAP-1A engines and affected blade part numbers, you must start borescope inspections (BSIs) of the high-pressure turbine (HPT) rotor stage 1 blades on or after December 29, 2025. Initial inspections must occur within 100 flight cycles after the blade accumulates 1,100 South Asia takeoffs, before certain cycles-since-new (Group 1: before 2,500 CSN; Group 2: before 5,100 CSN), or within 100 flight cycles after the AD effective date, whichever is later; then repeat at intervals not exceeding 150 flight cycles (Group 1) or 300 flight cycles (Group 2).
Inspection and replacement cost estimates
The FAA estimates each borescope inspection (BSI) costs $340 (4 work-hours at $85/hour). If replacement of an HPT rotor stage 1 blade set is needed, the AD lists on-condition costs with parts and labor totaling $1,000,950 per engine. The FAA also estimates this AD affects 0 engines on U.S. registry, so the agency lists $0 cost to U.S. operators in its estimate.
Applies only to specific blades and South Asia flights
This AD applies only to LEAP-1A engines with HPT rotor stage 1 blades having part numbers P/N 2747M92P01, P/N 2553M91G03, P/N 2553M91G05, P/N 2553M91G06, P/N 2553M91G07, or P/N 2553M91G08 that have accumulated more than 1,100 South Asia takeoffs. The South Asia region is defined as Bangladesh, Bhutan, India, Maldives, Nepal, and Sri Lanka.
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