More Boeing bolt checks: FAA's endless fin-tinkering saga.
Published Date: 8/12/2026
Proposed Rule
Summary
The FAA proposes to supersede Airworthiness Directive (AD) 2022-15-01, which applies to certain The Boeing Company Model 787-8, 787-9, and 787-10 airplanes. AD 2022-15-01 requires inspecting certain vertical fin tension bolt holes; reviewing the bolt sealant application installation procedure in the existing maintenance or inspection program, as applicable; checking maintenance records to determine the replacement status of vertical fin tension bolts; and doing applicable on-condition actions. Since the FAA issued AD 2022-15-01, the FAA has determined that optional sealant types allowed by that AD may not provide sufficient time to complete all bolt installations. The FAA has also received additional reports of corrosion that, in some cases, was more severe than expected. As a result, the FAA has determined that the compliance times for certain actions must be reduced. This proposed AD would, for certain airplanes, continue to require certain actions required by AD 2022-15-01 with reduced compliance times. For certain airplanes, this proposed AD would also require reviewing maintenance records to determine whether a correct sealant application method was used and performing applicable on-condition actions. The FAA is proposing this AD to address the unsafe condition on these products.
Analyzed Economic Effects
4 provisions identified: 0 benefits, 4 costs, 0 mixed.
Required Inspections and Records Review
If you operate Boeing Model 787-8, 787-9, or 787-10 airplanes, the FAA proposes to require detailed inspections of 16 vertical fin tension bolt holes, reviews of maintenance/inspection programs for correct sealant application, and records reviews to determine bolt replacement and sealant method. The proposed AD would retain certain actions from AD 2022-15-01 but with reduced compliance times and would apply as specified in Boeing Alert Requirements Bulletin B787-81205-SB550010-00 RB, Issue 002, dated March 11, 2026.
Per-Aircraft Compliance Cost Estimate
The FAA estimates the basic inspection, sealant application, and bolt/nut installation will cost $38,260 per airplane (6 work-hours x $85/hour = $510 labor plus $37,750 parts). The FAA estimates this proposed AD would affect 116 U.S.-registered airplanes, giving an aggregate estimated cost on U.S. operators of up to $4,438,160 for those actions.
Potential Additional On-Condition Repairs
Based on inspection results, operators may need on-condition actions such as applying sealant and finish, installing new vertical fin tension bolts and barrel nuts, detailed inspections for corrosion and repairs, and other repairs. The FAA provides per-action cost estimates matching the inspection cost ($38,260 for 6 labor hours plus parts) but states it cannot determine how many aircraft will require these on-condition repairs.
Maintenance Program Revision Burden
The FAA estimates revising an operator's maintenance or inspection program to include the correct sealant application procedure will take an average of 90 work-hours per operator, at $85 per hour, for an estimated average total cost per operator of $7,650. This is a per-operator cost (not per-airplane).
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