FAA Orders Boeing 787 Fuel-Tank Sealant Checks After Missed Inspections
Published Date: 11/2/2026
Rule
Summary
The FAA is making sure certain Boeing 787 airplanes get a thorough check on their wing fuel tank sealants because some missed inspections during production. Starting December 7, 2026, airlines must inspect and test these sealants to keep flights safe. This might cost some time and money but keeps everyone flying worry-free!
Analyzed Economic Effects
4 provisions identified: 2 benefits, 1 costs, 1 mixed.
Mandatory sealant inspections on Boeing 787s
If you operate or fly on certain Boeing Model 787-8, 787-9, or 787-10 airplanes identified in Boeing Alert Requirements Bulletin B787-81205-SB570053-00 RB (Issue 001, dated November 5, 2025), the FAA requires a detailed inspection of certain sealant installations and an adhesion test in the left, right, and center wing side-of-body areas (and the area between side-of-body rib and rib 2). These inspections and any required on-condition actions must be done in accordance with the Boeing Alert Requirements Bulletin, and the AD is effective December 7, 2026.
Estimated inspection cost per airplane
The FAA estimates the required detailed inspection and adhesion test will take 34 work-hours at $85 per hour, for an estimated cost of $2,890 per airplane. The FAA estimates this AD affects 60 U.S.-registered airplanes, for a total estimated cost to U.S. operators of $173,400.
On-condition repair costs may be unknown or covered by warranty
The FAA states it has no definitive data to estimate costs for on-condition repairs resulting from the inspections, and the manufacturer has indicated some or all of those costs may be covered under warranty. That means operators may face additional, unspecified repair costs, though warranty coverage could reduce their out-of-pocket expense.
Approved repair methods using Boeing AWLs
For sealant installation repairs, the AD allows repairs that comply with Airworthiness Limitations (AWLs) Nos. 28-AWL-83, 28-AWL-120, 28-AWL-121, 28-AWL-123, 28-AWL-124, and 28-AWL-125 in Boeing 787 Special Compliance Items/Airworthiness Limitations D011Z009-03-04 (dated August 2018) to be used as acceptable repairs. Operators may also use applicable Boeing Aircraft Maintenance Manual procedures provided each repair meets the AWL requirements.
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