Airworthiness Directives; The Boeing Company Airplanes

DEPARTMENT OF TRANSPORTATION <SUBAGY>Federal Aviation Administration</SUBAGY> <CFR>14 CFR Part 39</CFR> <DEPDOC>[Docket No. FAA-2025-3985; Project Identifier AD-2025-00493-T]</DEPDOC> <RIN>RIN 2120-AA64</RIN> <SUBJECT>Airworthiness Directives; The Boeing Company Airplanes</SUBJECT> <HD SOURCE="HED">AGENCY:</HD> Federal Aviation Administration (FAA), DOT. <HD SOURCE="HED">ACTION:</HD> Notice of proposed rulemaking (NPRM). <SUM> <HD SOURCE="HED">SUMMARY:</HD> The FAA proposes to adopt a new airworthiness directive (AD) for certain The Boeing Company Model 737-8, 737-9, and 737-8200 (737 MAX) airplanes. This proposed AD was prompted by reports of cracks in the bear strap at the forward upper corner of the forward galley door cutout. This proposed AD would require an inspection of the fuselage skin for existing repairs and applicable on-condition actions. The FAA is proposing this AD to address the unsafe condition on these products. </SUM> <EFFDATE> <HD SOURCE="HED">DATES:</HD> The FAA must receive comments on this proposed AD by January 9, 2026. </EFFDATE> <HD SOURCE="HED">ADDRESSES:</HD> You may send comments, using the procedures found in 14 CFR 11.43 and 11.45, by any of the following methods: • <E T="03">Federal eRulemaking Portal:</E> Go to <E T="03">regulations.gov.</E> Follow the instructions for submitting comments. • <E T="03">Fax:</E> 202-493-2251. • <E T="03">Mail:</E> U.S. Department of Transportation, Docket Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590. • <E T="03">Hand Delivery:</E> Deliver to Mail address above between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. <E T="03">AD Docket:</E> You may examine the AD docket at <E T="03">regulations.gov</E> under Docket No. FAA-2025-3985; 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. <E T="03">Material Incorporated by Reference:</E> • 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 <E T="03">myboeingfleet.com.</E> • 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 <E T="03">regulations.gov</E> under Docket No. FAA-2025-3985. <FURINF> <HD SOURCE="HED">FOR FURTHER INFORMATION CONTACT:</HD> Luis Cortez-Muniz, Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-231-3958; email: <E T="03">luis.a.cortez-muniz@faa.gov.</E> </FURINF> <SUPLINF> <HD SOURCE="HED">SUPPLEMENTARY INFORMATION:</HD> <HD SOURCE="HD1">Comments Invited</HD> 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 <E T="02">ADDRESSES</E> section. Include “Docket No. FAA-2025-3985; Project Identifier AD-2025-00493-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 <E T="03">regulations.gov,</E> including any personal information you provide. The agency will also post a report summarizing each substantive verbal contact received about this NPRM. <HD SOURCE="HD1">Confidential Business Information</HD> 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 Luis Cortez-Muniz, Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-231-3958; email: <E T="03">luis.a.cortez-muniz@faa.gov.</E> Any commentary that the FAA receives that is not specifically designated as CBI will be placed in the public docket for this rulemaking. <HD SOURCE="HD1">Background</HD> The FAA has received reports of cracks in the bear strap at the forward upper corner of the forward galley door cutout on Model 737-600, -700, -700C, -800, -900, and -900ER series (737NG) airplanes. A Boeing investigation determined that the cracks were caused by high operating stresses in the fuselage skin and bear strap due to stress concentration at the corner of the door cutout. Although no cracks have been reported in the same areas on Boeing 737 MAX airplanes, they have a similar design and build process, making those airplanes susceptible to the same crack condition. This condition, if not addressed may lead to the inability of a principal structural element to sustain limit loads and adversely affect the structural integrity of the airplane. Boeing issued Alert Requirements Bulletin 737-53A1407 RB, dated December 20, 2022, to address the identified unsafe condition for Model 737NG airplanes. Subsequently, the FAA issued AD 2024-06-01, Amendment 39-22706 (89 FR 27376, April 17, 2024) to require an inspection of the fuselage skin and the bear strap at the forward galley door cutout forward upper corner for existing repairs, and applicable related investigative and corrective actions, as specified in Boeing Alert Requirements Bulletin 737-53A1407 RB, dated December 20, 2022. <HD SOURCE="HD1">FAA's Determination</HD> 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. <HD SOURCE="HD1">Material Incorporated by Reference Under 1 CFR Part 51</HD> The FAA reviewed Boeing Alert Requirements Bulletin 737-53A1408 RB, dated December 20, 2024. This material specifies procedures for an external general visual inspection of the fuselage skin for any repair and applicable on-condition actions. On-condition actions include repetitive detailed inspection for cracking of the fuselage skin; repetitive external surface high frequency eddy current (HFEC) inspections of the fuselage skin at certain fastener locations and the fuselage skin and bear strap along the edge of door corner radius for cracking; repetitive external subsurface low frequency eddy current (LFEC) inspection of the bear strap at certain fastener locations for cracking; and obtaining instructions from Boeing for alternative inspections or for crack 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 <E T="02">ADDRESSES</E> section. <HD SOURCE="HD1">Proposed AD Requirements in This NPRM</HD> 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 <E T="03">regulations.gov</E> under Docket No. FAA-2025-3985. <HD SOURCE="HD1">Costs of Compliance</HD> The FAA estimates that this AD, if adopted as proposed, would affect 471 airplanes of U.S. registry. The FAA estimates the following costs to comply with this proposed AD: <GPOTABLE COLS="5" OPTS="L2,i1" CDEF="s50,r50,12,r50,r50"> <TTITLE>Estimated Costs</TTITLE> <CHED H="1">Action</CHED> <CHED H="1">Labor cost</CHED> <CHED H="1">Parts cost</CHED> Cost on U.S. operators </CHED> <ROW> <ENT I="01">External general visual inspection for repairs</ENT> <ENT>1 work-hour × $85 per hour = $85</ENT> <ENT>$0</ENT> <ENT>$85</ENT> <ENT>$40,035.</ENT> </ROW> <ROW> <ENT I="01">External detailed and eddy current inspections for cracks</ENT> <ENT>Up to 4 work-hours × $85 per hour = $340 per inspection cycle</ENT> <ENT>0</ENT> <ENT>Up to $340</ENT> <ENT>Up to $160,140 per inspection cycle.</ENT> </ROW> </GPOTABLE> The FAA has received no definitive data on which to base the cost estimates for the on-condition repairs or for the alternative inspections specified in this proposed AD. <HD SOURCE="HD1">Authority for This Rulemaking</HD> 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 ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Preview showing 10k of 17k characters. Full document text is stored and available for version comparison. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━