FAA orders wing crack inspections on certain Boeing 787s

The US Federal Aviation Administration has issued an airworthiness directive requiring operators of dozens of Boeing 787 aircraft to inspect their wings for possible cracks. The rule takes effect on October 1, 2026, following a proposal published for comment in March.

The directive stems from a Boeing investigation into manufacturing errors and excessive preload forces on splice plates connected to the lower wing skins. According to the FAA, gaps in shims may have exceeded technical specifications, and high tensile forces on these components could cause fatigue cracks to form at fastener holes. Left undetected, such cracks could spread and eventually compromise the ability to fly safely.

The issue traces back to 2019, when Boeing identified an outdated method for measuring shims, according to a company spokesperson cited by a US newspaper. At that time and in subsequent years, the concern mainly involved fuselage section joints rather than wings.

In August 2025, Boeing sent updated wing inspection instructions to affected 787 operators through an alert requirements bulletin. The new FAA directive formalizes those inspections as mandatory for the affected fleet.

No operator was named in connection with the directive beyond a general reference to American Airlines as one operator of the Dreamliner type. The FAA has not disclosed how many aircraft in total are covered by the mandate.