The U.S. Federal Aviation Administration (FAA) has issued a new airworthiness directive (AD 2026-17-02) mandating repetitive fatigue inspections on certain Boeing 787 Dreamliners. The order, effective October 1, 2026, comes after Boeing identified potential manufacturing errors that could lead to cracking in the primary wing structure.
The Issue
The problem stems from potentially excessive shim gaps and preload forces at the lower side-of-body splice plates, where they join the lower outboard wing skins. According to the FAA, if undetected, cracks could form around fastener holes and weaken the structure below required load capability.
Affected Aircraft
Boeing’s requirements bulletin, issued in August 2025, identifies 77 affected aircraft worldwide:
49 Boeing 787-8s
27 Boeing 787-9s
1 Boeing 787-10
Of these, 17 are U.S.-registered.
Operator Impact
Analysis of fleet records shows the largest concentrations:
Air India: 9 affected 787-8s
American Airlines: 7 aircraft
Qatar Airways: 7 aircraft
United Airlines: 7 aircraft
Required Actions
Operators must conduct repetitive ultrasonic inspections and, depending on configuration, detailed visual inspections of the affected wing structures. Any cracking found requires immediate repair.
Boeing’s Response
Boeing stated it identified the outdated shim measurement method in 2019 and corrected the production process. The company issued updated operator guidance in August 2025 and maintains that affected aircraft can continue normal operations while inspections are carried out.
Background Context
This directive adds to previous scrutiny of B787 manufacturing tolerances, including:
A 2024 FAA investigation into engineer Sam Salehpour’s allegations about structural gaps
Separate fuselage manufacturing issues that halted deliveries in 2021-2022
This article is based on reporting by Dirk Andrei Salcedo for ch-aviation.