Boeing 767 Wings Get Mandatory Crack Checks
Published Date: 3/12/2026
Rule
Summary
The FAA is making sure certain Boeing 767 airplanes stay safe by requiring special crack inspections around key wing parts. If cracks are found, repairs must be done to keep flights secure. This rule starts April 16, 2026, and helps prevent costly problems down the line for airlines and passengers alike.
Analyzed Economic Effects
5 provisions identified: 2 benefits, 3 costs, 0 mixed.
Mandatory crack inspections on certain 767s
If you fly on certain Boeing 767-200, -300, -300F, or -400ER airplanes, the FAA now requires open-hole high frequency eddy current (HFEC) inspections of the fastener holes where the underwing longeron (UWL) fitting attaches, to find cracks before they reach a critical length. This AD is effective April 16, 2026 and applies to the airplanes identified in Boeing Alert Requirements Bulletin 767-57A0148 RB, dated October 10, 2024.
Per-airplane inspection cost for operators
If you operate affected Boeing 767 airplanes, each required open-hole HFEC inspection is estimated at 170 work-hours × $85/hour = $14,450 per airplane. The FAA estimates 600 U.S.-registered airplanes are affected, with total estimated U.S. operator cost of $8,670,000 for the initial inspection.
On-condition repair costs if cracks found
If inspections find cracks, operators may need repairs such as fitting replacement, hole oversize repair, or part repairs. The FAA estimates a replacement action at 19 work-hours × $85/hour ($1,615 labor) plus $15,270 parts for a total estimated cost per replacement of $16,885. Repetitive HFEC inspections are estimated at $14,450 each.
Fuel-tank cap-seal requirement and thickness
The AD requires cap seals be applied to fasteners, fastener heads, threads, and collars inside the fuel tank with at least the minimum thickness dimensions shown in figure 1 to paragraph (h)(4) of the AD. The AD also requires certain fasteners installed per specified steps in the Boeing requirements bulletin to be cap sealed.
Compliance timing tied to fitting replacement
For initial inspections, where the Boeing bulletin lists compliance times measured from replacement of the underwing longeron fitting, this AD requires calculating that compliance time from when the fitting was replaced using either Boeing Alert Requirements Bulletin 767-57A0148 RB (Oct 10, 2024) or Revisions 1–5 of Boeing Alert Service Bulletin 767-57A0126 (dates: Nov 9, 2011; Mar 12, 2012; Nov 8, 2012; Apr 17, 2014; Apr 7, 2016). Some tables specify a compliance time of within 22,000 flight cycles or 80,000 flight hours after that replacement, whichever occurs first.
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