FAA Expands Airbus Door Crack Checks to More Models
Published Date: 2/25/2026
Proposed Rule
Summary
The FAA wants to update safety rules for certain Airbus airplanes to include more models and clarify repair steps. Pilots and airlines flying these planes will need to keep checking door parts for cracks and fix them if needed. Comments on this plan are open until April 13, 2026, and these changes help keep flights safe without big costs.
Analyzed Economic Effects
6 provisions identified: 1 benefits, 5 costs, 0 mixed.
Mandatory rototest inspections for door fittings
If you operate the listed Airbus airplanes, you must do repetitive rototest inspections of the door stop fitting holes (positions 1 and 7 at fuselage frame 16 and 20 on left- and right-hand sides) and repair any cracking found. These inspection and repair actions are retained from AD 2022-02-11 and would continue under the proposed AD.
FAA cost estimates per airplane and industry totals
The FAA estimates the proposed AD affects 1,979 U.S. airplanes. Estimated cost per airplane: up to $2,805 for retained CEO actions (1,363 CEO airplanes) and up to $2,890 for repetitive inspections for 616 NEO airplanes. The FAA estimates aggregate U.S. operator costs up to $3,823,215 for CEO airplanes and up to $1,780,240 for NEO airplanes; on-condition repairs are estimated at $4,685 per occurrence (51 work-hours + $350 parts).
AD addresses unsafe cracking to protect structural integrity
The FAA says cracks were detected on web holes and intercostal fitting holes at door stop fittings on affected frames, and that cracking could affect structural integrity. The AD is issued to require inspections and repairs to address that unsafe condition and protect flight safety.
Applicability expanded to NEO and more models
The proposed AD expands which Airbus models must comply to include many NEO variants and additional A319/A320/A321 types (lists in paragraph (c) mirror EASA AD 2025-0111). As written, the proposal applies to a total of 1,979 U.S.-registered airplanes.
Reporting and paperwork timeline requirements
Operators must report results only when cracked intercostals have been replaced using repair instruction R53113118, R53113626, or R53113627. If the inspection is done on or after the AD's effective date, submit the report within 30 days after the inspection; if done before the AD's effective date, submit within 30 days after the AD's effective date. The Paperwork Reduction Act estimate is about 1 hour per response (OMB Control Number 2120-0056).
Repair approvals must follow specified authorities
When repaired, affected areas must be repaired using a method approved by the Manager, AIR-520 (FAA), or EASA, or Airbus SAS's EASA Design Organization Approval (DOA) with the DOA-authorized signature. After such approved repair, operators must accomplish the next due inspection per the approved repair instructions.
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