Boeing to Rework 30 Stored 777X Jets Before Delivery

Boeing will have to modify about 30 finished 777X aircraft now in storage before any can go to customers, the company's chief executive said recently. Design changes turned up during the jet's long certification flight test program, which created the extra work.

Older airframes need the most extensive rework, including structural changes. Newer builds require only minor software and systems updates. The CEO called the process a "change incorporation" that has to be finished before delivery.

The 777X, Boeing's newest widebody, has seen years of delays. Certification flight testing ended in 2024, but the aircraft still awaits final approval from regulators. Boeing has built dozens of the jets and stores them at facilities in Washington state and elsewhere.

No timeline was given for the rework. The company did not say whether it would affect the delivery schedule, which is already behind original targets. Boeing has said it expects to begin 777X deliveries in 2026, though that date may slip further if the modifications prove more extensive than anticipated.

The disclosure shows the difficulty of incorporating design changes into aircraft built before the final configuration was locked in. Boeing has faced similar challenges on other programs, including the 787 Dreamliner, which required extensive inspections and rework after production flaws were discovered.

The 777X program has accumulated more than 500 orders from airlines including Emirates, Qatar Airways, and Lufthansa. Those customers have waited for years, and some have expressed frustration with the delays. The rework announcement adds another hurdle before the first delivery can take place.