FAA mandates Boeing 787 part swaps to fix wing woes
Published Date: 10/8/2026
Rule
Summary
If you own or operate Boeing 787-8, 787-9, or 787-10 planes, this new FAA rule updates safety checks and parts to keep your aircraft flying safely. It replaces an older rule by requiring a new part swap and updated maintenance steps, effective November 12, 2026. These changes help prevent problems with the wing slats and might mean some extra maintenance costs but boost safety big time.
Analyzed Economic Effects
4 provisions identified: 0 benefits, 4 costs, 0 mixed.
Mandatory actuator replacement on 787 outboard slats
If you own or operate Boeing 787-8, 787-9, or 787-10 airplanes identified in Boeing Alert Requirements Bulletin B787-81205-SB270055-00 RB, Issue 002, you must replace the leading edge outboard geared rotary actuator (GRA) with a leading edge outboard lockout actuator (LEOLA) at specified outboard slat locations. The FAA estimates the replacement cost at $32,375 per airplane (9 work-hours x $85/hr = $765 plus $31,610 parts). This AD is effective November 12, 2026.
New maintenance program certification requirement
Operators must revise their maintenance or inspection program to incorporate a new certification maintenance requirement (CMR) (item 27-CMR-14: functionally check the Leading Edge Power Drive Unit half system torque brake). The FAA estimates this maintenance-program revision takes 90 work-hours and costs $7,650 on average per operator (90 x $85/hr).
Estimated U.S. operator fleet cost and affected fleet size
The FAA estimates this AD affects 174 U.S.-registered Boeing 787 airplanes. Using FAA estimates, a single replacement action across the U.S. fleet would cost about $5,633,250 (174 x $32,375); each retained operational check across the U.S. fleet is estimated at $118,320 (174 x $680); and the AFM revision across the U.S. fleet is estimated at $14,790 (174 x $85). The FAA also estimates an average per-operator maintenance-program revision cost of $7,650.
Continued operational checks and AFM flap restriction
This AD retains prior requirements from AD 2019-20-07 to perform repetitive operational checks of the leading edge outboard slats and to revise the airplane flight manual (AFM) to prohibit flap retraction under icing conditions after landing. The FAA estimates each operational check costs 8 work-hours x $85/hr = $680 per check, and the AFM revision cost is 1 work-hour x $85 = $85 per airplane. The AFM revision was required within 60 days after October 11, 2019 under the prior AD.
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