Boeing 777 Needs More Fuel Tank Prods: FAA's Endless Safety Dance
Published Date: 7/28/2026
Rule
Summary
The FAA is superseding Airworthiness Directive (AD) 2024-19- 14, which applied to certain The Boeing Company Model 777-200, 777- 200LR, 777-300ER, and 777F series airplanes. AD 2024-19-14 required repetitive inspections and bond resistance measurement of the bonding jumpers on the first fuel feed tube installed immediately forward of the wing front spar at the left and right main fuel tank penetrations and applicable corrective actions. This AD was prompted by a determination that additional inspections are required to address the unsafe condition. This AD requires repetitive detailed inspections (DETs), repetitive bond resistance measurement, and applicable on- condition actions. This AD also expands the applicability and requires revising the existing maintenance or inspection program, as applicable, to incorporate a certain airworthiness limitation. The FAA is issuing this AD to address the unsafe condition on these products.
Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Mandatory 777 fuel-system inspections
The FAA requires repetitive detailed inspections (DETs) and bond resistance measurements of bonding jumpers on specified engine fuel feed tubes for all Boeing Model 777-200, -200LR, -300, -300ER, and 777F airplanes. The rule supersedes AD 2024-19-14, is effective September 1, 2026, expands applicability to all listed 777 series airplanes, and mandates on-condition corrective actions to address latent lightning-protection failures that could create ignition sources inside fuel tanks.
Maintenance program revision deadline
Within 60 days after the AD's effective date (i.e., by October 31, 2026), operators must revise their existing maintenance or inspection program to incorporate the AD's Critical Design Configuration Control Limitations (CDCCLs). The FAA estimates a one-time average cost of $7,650 per operator to perform the required maintenance program revision (90 work-hours × $85/hour).
Recurring inspections and repair costs
Operators must perform recurring inspections and resistance measurements: $255 per inspection cycle under Boeing Alert Requirements Bulletin 777-28A0097 RB and $376 per inspection cycle under Boeing Alert Requirements Bulletin 777-28A0098 RB (the latter approximately every 3 years). Depending on findings, on-condition repairs can cost up to $2,211 per operator; the FAA estimates a three-year per-operator low-case cost of $8,791 (excluding on-condition repairs) and a high-case cost of $11,002 (including on-condition repairs).
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