Boeing 757s Face Mandatory Crack Hunts from FAA
Published Date: 4/2/2026
Proposed Rule
Summary
The FAA wants all Boeing 757-300 airplanes to get new inspections to catch cracks in key parts of the plane’s frame before they become a problem. Airlines will need to check for past repairs and do regular crack inspections to keep flights safe. Comments on this plan are open until May 18, 2026, and these checks might cost some time and money but will keep everyone flying safely.
Analyzed Economic Effects
2 provisions identified: 1 benefits, 1 costs, 0 mixed.
New Inspections for Boeing 757-300
The FAA proposes required inspections for all Boeing Model 757-300 airplanes to find cracks in the upper frames around the uppermost fastener common to the fail-safe chord at fuselage frame splices between stringers S-13 and S-14, from station 1380 to 1620. The rule would require a maintenance-records check or general visual inspection for prior repairs, repetitive detailed inspections for cracks, and on-condition actions including contacting Boeing for repair instructions.
Estimated Compliance Costs for Operators
The FAA estimates the proposed AD would affect 37 U.S.-registered Boeing 757-300 airplanes. A general visual inspection or maintenance-records check is estimated at up to 70 work-hours at $85/hour (up to $5,950 per airplane; up to $220,150 on U.S. operators). A detailed inspection is estimated at 4 work-hours at $85/hour ($340 per airplane per inspection cycle; $12,580 per inspection cycle on U.S. operators). The FAA has no definitive cost estimate for alternative inspections and on-condition repairs.
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Key Dates
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