FAA Proposes Airworthiness Directive for Boeing 787 Manufacturing Errors
Summary
The Federal Aviation Administration (FAA) has proposed a new airworthiness directive concerning manufacturing errors in Boeing 787 airplanes. This proposed rule is open for public comment for 45 days.
What changed
The Federal Aviation Administration (FAA) has issued a proposed rule concerning airworthiness directives for Boeing 787 airplanes, specifically addressing manufacturing errors. The document, published on March 13, 2026, is a proposed rule and is subject to a public comment period.
Regulated entities, primarily manufacturers and operators of Boeing 787 aircraft, should review the proposed directive to understand the specific manufacturing errors identified and the proposed corrective actions. Interested parties have 45 days from the publication date to submit public comments, with the comment period closing on April 27, 2026. Failure to comply with the final airworthiness directive, once issued, could result in enforcement actions.
What to do next
- Review proposed airworthiness directive for Boeing 787 manufacturing errors.
- Submit public comments by April 27, 2026.
- Prepare for compliance with final airworthiness directive requirements.
Source document (simplified)
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Proposed Rule
Airworthiness Directives; The Boeing Company Airplanes
A Proposed Rule by the Federal Aviation Administration on 03/13/2026
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- Document Details Published Content - Document Details Agencies Department of Transportation Federal Aviation Administration Agency/Docket Numbers Docket No. FAA-2026-2295 Project Identifier AD-2025-01361-T CFR 14 CFR 39 Document Citation 91 FR 12312 Document Number 2026-05007 Document Type Proposed Rule Pages 12312-12314 (3 pages) Publication Date 03/13/2026 RIN 2120-AA64 Published Content - Document Details
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- Document Details Published Content - Document Details Agencies Department of Transportation Federal Aviation Administration Agency/Docket Numbers Docket No. FAA-2026-2295 Project Identifier AD-2025-01361-T CFR 14 CFR 39 Document Citation 91 FR 12312 Document Number 2026-05007 Document Type Proposed Rule Pages 12312-12314 (3 pages) Publication Date 03/13/2026 RIN 2120-AA64 Published Content - Document Details
- Document Dates Published Content - Document Dates Comments Close 04/27/2026 Dates Text The FAA must receive comments on this proposed AD by April 27, 2026. Published Content - Document Dates
Table of Contents Enhanced Content - Table of Contents This table of contents is a navigational tool, processed from the
headings within the legal text of Federal Register documents.
This repetition of headings to form internal navigation links
has no substantive legal effect.- AGENCY:
- ACTION:
- SUMMARY:
- DATES:
- ADDRESSES:
- FOR FURTHER INFORMATION CONTACT:
- SUPPLEMENTARY INFORMATION:
- Comments Invited
- Confidential Business Information
- Background
- FAA's Determination
- Material Incorporated by Reference Under 1 CFR Part 51
- Proposed AD Requirements in This NPRM
- Costs of Compliance
- Authority for This Rulemaking
- Regulatory Findings
- List of Subjects in 14 CFR Part 39
- The Proposed Amendment
- PART 39—AIRWORTHINESS DIRECTIVES
- (a) Comments Due Date
- (b) Affected ADs
- (c) Applicability
- (d) Subject
- (e) Unsafe Condition
- (f) Compliance
- (g) Required Actions
- (h) Exceptions to Requirements Bulletin Specifications
- (i) Alternative Methods of Compliance (AMOCs)
- (j) Additional Information
- (k) Material Incorporated by Reference Enhanced Content - Table of Contents
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AD-2025-01361-T; The Boeing Company Model 787-10, 787-8, 787-9 series airplanes; lower side of body splice plate and wing structure
Comment Due Date 04/27/2026 Docket ID FAA-2026-2295 Supporting Documents U.S. DOT/FAA - Supplemental AD Documents Enhanced Content - Regulations.gov Data
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Department of Transportation
Federal Aviation Administration
- 14 CFR Part 39
- [Docket No. FAA-2026-2295; Project Identifier AD-2025-01361-T]
- RIN 2120-AA64 ( printed page 12312) # AGENCY:
Federal Aviation Administration (FAA), DOT.
ACTION:
Notice of proposed rulemaking (NPRM).
SUMMARY:
The FAA proposes to adopt a new airworthiness directive (AD) for certain The Boeing Company Model 787-8, 787-9, and 787-10 airplanes. This proposed AD was prompted by a Boeing investigation for manufacturing errors and excessive preload forces at the lower side of body (SOB) splice plates common to the lower outboard wing skins. That investigation concluded that shim gaps may have exceeded engineering allowances, and high pull up forces on the components may cause fatigue cracks to form at the fastener holes. This proposed AD would require, depending on configuration, repetitive ultrasonic (UT) inspections at certain splice plates, rear spar terminal fittings, lower chords, front spar terminal fittings, and jack pads for any cracks; repetitive detailed inspections (DET) of certain splice plates for any cracks; and applicable on-condition actions. The FAA is proposing this AD to address the unsafe condition on these products.
DATES:
The FAA must receive comments on this proposed AD by April 27, 2026.
ADDRESSES:
You may send comments, using the procedures found in 14 CFR 11.43 and 11.45, by any of the following methods:
- Federal eRulemaking Portal: Go to regulations.gov. Follow the instructions for submitting comments.
- Fax: 202-493-2251.
- Mail: U.S. Department of Transportation, Docket Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
- Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. AD Docket: You may examine the AD docket at regulations.gov under Docket No. FAA-2026-2295; or in person at Docket Operations between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this NPRM, any comments received, and other information. The street address for Docket Operations is listed above.
Material Incorporated by Reference:
- For Boeing material identified in this proposed AD, contact Boeing Commercial Airplanes, Attention: Contractual & Data Services (C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; telephone 562-797-1717; website myboeingfleet.com.
- You may view this material at the FAA, Airworthiness Products Section, Operational Safety Branch, 2200 South 216th St., Des Moines, WA. For information on the availability of this material at the FAA, call 206-231-3195. It is also available at regulations.gov under Docket No. FAA-2026-2295.
FOR FURTHER INFORMATION CONTACT:
Joseph Hodgin, Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-231-3962; email: joseph.j.hodgin@faa.gov.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites you to send any written relevant data, views, or arguments about this proposal. Send your comments using a method listed under the ADDRESSES section. Include “Docket No. FAA-2026-2295; Project Identifier AD-2025-01361-T” at the beginning of your comments. The most helpful comments reference a specific portion of the proposal, explain the reason for any recommended change, and include supporting data. The FAA will consider all comments received by the closing date and may amend this proposal because of those comments.
Except for Confidential Business Information (CBI) as described in the following paragraph, and other information as described in 14 CFR 11.35, the FAA will post all comments received, without change, to regulations.gov, including any personal information you provide. The agency will also post a report summarizing each substantive verbal contact received about this NPRM.
Confidential Business Information
CBI is commercial or financial information that is both customarily and actually treated as private by its owner. Under the Freedom of Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public disclosure. If your comments responsive to this NPRM contain commercial or financial information that is customarily treated as private, that you actually treat as private, and that is relevant or responsive to this NPRM, it is important that you clearly designate the submitted comments as CBI. Please mark each page of your submission containing CBI as “PROPIN.” The FAA will treat such marked submissions as confidential under the FOIA, and they will not be placed in the public docket of this NPRM. Submissions containing CBI should be sent to Joseph Hodgin, Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-231-3962; email: joseph.j.hodgin@faa.gov. Any commentary that the FAA receives that is not specifically designated as CBI will be placed in the public docket for this rulemaking.
Background
The FAA has received a report indicating that a Boeing investigation for manufacturing errors and excessive preload forces at the lower SOB splice plates common to the lower outboard wing skins concluded that shim gaps may have exceeded engineering allowances. High pull up forces on the components may cause fatigue cracks to form at the fastener holes. Structural assessment of the condition has found that the existing structural inspection program for the affected aircraft is not adequate to detect cracking in principal structural elements with sufficient probability prior to the loss of limit load capability. This condition, if not addressed, could result in undetected fatigue cracks that can grow to weaken primary wing structure until it cannot ( printed page 12313) sustain limit load and result in subsequent loss of continued safe flight and landing.
FAA's Determination
The FAA is issuing this NPRM after determining that the unsafe condition described previously is likely to exist or develop on other products of the same type design.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025. This material specifies procedures for performing repetitive UT inspections depending on configuration, repetitive UT inspections at splice plate No. 1 and No. 2, rear spar terminal fittings, lower chords, front spar terminal fittings, and jack pads for any cracks; repetitive DET of splice plates No. 1 and No. 2 for any cracks; and applicable on-condition actions. On-condition actions include repair.
This material is reasonably available because the interested parties have access to it through their normal course of business or by the means identified in the ADDRESSES section.
Proposed AD Requirements in This NPRM
This proposed AD would require accomplishing the actions specified in the material already described, except for any differences identified as exceptions in the regulatory text of this proposed AD. For information on the procedures and compliance times, see this material at regulations.gov under Docket No. FAA-2026-2295.
Costs of Compliance
The FAA estimates that this AD, if adopted as proposed, would affect 17 airplanes of U.S. registry. The FAA estimates the following costs to comply with this proposed AD:
| Action | Labor cost | Parts cost | Cost per product | Cost on U.S. operators |
| --- | --- | --- | --- | --- |
| UT and DET inspections | Up to 286 work hours × $85 per hour = $24,310 per inspection cycle | $0 | Up to $24,310 per inspection cycle | Up to $413,270 per inspection cycle. |
The FAA has received no definitive data on which to base the cost estimates for the on-condition repairs specified in this proposed AD.
The FAA has included all known costs in its cost estimate. According to the manufacturer, however, some or all of the costs of this proposed AD may be covered under warranty, thereby reducing the cost impact on affected operators.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, section 106, describes the authority of the FAA Administrator. Subtitle VII: Aviation Programs, describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in Subtitle VII, Part A, Subpart III, Section 44701: General requirements. Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action.
Regulatory Findings
The FAA determined that this proposed AD would not have federalism implications under Executive Order 13132. This proposed AD would not have a substantial direct effect on the States, on the relationship between the national government and the States, or on the distribution of power and responsibilities among the various levels of government.
For the reasons discussed above, I certify this proposed regulation:
(1) Is not a “significant regulatory action” under Executive Order 12866,
(2) Would not affect intrastate aviation in Alaska, and
(3) Would not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
- Air transportation
- Aircraft
- Aviation safety
- Incorporation by reference
- Safety
The Proposed Amendment
Accordingly, under the authority delegated to me by the Administrator, the FAA proposes to amend 14 CFR part 39 as follows:
PART 39—AIRWORTHINESS DIRECTIVES
- The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
§ 39.13 [Amended] 2. The FAA amends § 39.13 by adding the following new airworthiness directive:
The Boeing Company: Docket No. FAA-2026-2295; Project Identifier AD-2025-01361-T.
(a) Comments Due Date
The FAA must receive comments on this airworthiness directive (AD) by April 27, 2026.
(b) Affected ADs
None.
(c) Applicability
This AD applies to The Boeing Company Model 787-8, 787-9, and 787-10 airplanes, certificated in any category, as identified in Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001 dated August 11, 2025.
(d) Subject
Air Transport Association (ATA) of America Code 57, Wings.
(e) Unsafe Condition
This AD was prompted by a Boeing investigation for manufacturing errors and excessive preload forces at the lower side of body splice plates common to the lower outboard wing skins. That investigation concluded that shim gaps may have exceeded engineering allowances and high pull up forces on the components may cause fatigue cracks to form at the fastener holes. The FAA is issuing this AD to address improper shim gaps that may lead to fatigue cracks. The unsafe condition, if not addressed, could result in undetected fatigue cracks that can grow to weaken primary wing structure until it cannot sustain limit load and result in subsequent loss of continued safe flight and landing. ( printed page 12314)
(f) Compliance
Comply with this AD within the compliance times specified, unless already done.
(g) Required Actions
Except as specified by paragraph (h) of this AD: At the applicable times specified in the “Compliance” paragraph of Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025, do all applicable actions identified in, and in accordance with, the Accomplishment Instructions of Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025.
Note 1 to paragraph (g): Guidance for accomplishing the actions required by this AD can be found in Boeing Alert Service Bulletin B787-81205-SB570048, Issue 001, dated August 11, 2025, which is referred to in Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025.
(h) Exceptions to Requirements Bulletin Specifications
(1) Where the Compliance Time columns of the tables in the “Compliance” paragraph of Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025, refer to the Issue 001 date of the Requirements Bulletin B787-81205-SB570048 RB, this AD requires using the effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025, specifies contacting Boeing for repair instructions: This AD requires doing the repair using a method approved in accordance with the procedures specified in paragraph (i) of this AD.
(i) Alternative Methods of Compliance (AMOCs)
(1) The Manager, AIR-520, Continued Operational Safety Branch, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. In accordance with 14 CFR 39.19, send your request to your principal inspector or responsible Flight Standards Office, as appropriate. If sending information directly to the manager of the Continued Operational Safety Branch, send it to the attention of the person identified in paragraph (j) of this AD. Information may be emailed to: AMOC@faa.gov. Before using any approved AMOC, notify your appropriate principal inspector, or lacking a principal inspector, the manager of the responsible Flight Standards Office.
(2) An AMOC that provides an acceptable level of safety may be used for any repair, modification, or alteration required by this AD if it is approved by The Boeing Company Organization Designation Authorization (ODA) that has been authorized by the Manager, AIR-520, Continued Operational Safety Branch, FAA, to make those findings. To be approved, the repair method, modification deviation, or alteration deviation must meet the certification basis of the airplane, and the approval must specifically refer to this AD.
(j) Additional Information
(1) For more information about this AD, contact Joseph Hodgin, Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-231-3962; email: joseph.j.hodgin@faa.gov.
(2) Material identified in this AD that is not incorporated by reference is available at the address specified in paragraph (k)(3) this AD.
(k) Material Incorporated by Reference
(1) The Director of the Federal Register approved the incorporation by reference of the material listed in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this material as applicable to do the actions required by this AD, unless the AD specifies otherwise.
(i) Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025.
(ii) [Reserved]
(3) For Boeing material identified in this AD, contact Boeing Commercial Airplanes, Attention: Contractual & Data Services (C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; telephone 562-797-1717; website myboeingfleet.com.
(4) You may view this material at the FAA, Airworthiness Products Section, Operational Safety Branch, 2200 South 216th St., Des Moines, WA. For information on the availability of this material at the FAA, call 206-231-3195.
(5) You may view this material at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email fr.inspection@nara.gov.
Issued on March 5, 2026.
Lona C. Saccomando,
Acting Deputy Director, Integrated Certificate Management Division, Aircraft Certification Service.
[FR Doc. 2026-05007 Filed 3-12-26; 8:45 am]
BILLING CODE 4910-13-P
Published Document: 2026-05007 (91 FR 12312)
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