Rule2026-17553
Airworthiness Directives; The Boeing Company Airplanes
Primary source
Metadata and text below are from the Federal Register, a public-domain U.S. government work. Always verify the official published version before relying on it for any legal matter.
Published
August 27, 2026
Effective
October 1, 2026
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA is adopting a new airworthiness directive (AD) for certain The Boeing Company Model 787-8, 787-9, and 787-10 airplanes. This 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 AD requires, 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 issuing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 91 Issue 165 (Thursday, August 27, 2026)</title>
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[Federal Register Volume 91, Number 165 (Thursday, August 27, 2026)]
[Rules and Regulations]
[Pages 55247-55250]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2026-17553]
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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;
Amendment 39-23445; AD 2026-17-02]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
certain The Boeing Company Model 787-8, 787-9, and 787-10 airplanes.
This 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 AD requires, 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 issuing this AD to address the unsafe condition on
these products.
DATES: This AD is effective October 1, 2026.
The Director of the Federal Register approved the incorporation by
reference
[[Page 55248]]
of a certain publication listed in this AD as of October 1, 2026.
ADDRESSES:
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> 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 final rule, any comments received, and other
information. The address for Docket Operations is U.S. Department of
Transportation, Docket Operations, M-30, West Building Ground Floor,
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
Material Incorporated by Reference:
<bullet> 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 <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
<bullet> 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 <a href="http://regulations.gov">regulations.gov</a> 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: <a href="/cdn-cgi/l/email-protection#c9a3a6baacb9a1e7a3e7a1a6adaea0a789afa8a8e7aea6bf"><span class="__cf_email__" data-cfemail="4b2124382e3b2365216523242f2c22250b2d2a2a652c243d">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Background
The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
CFR part 39 by adding an AD that would apply to certain The Boeing
Company Model 787-8, 787-9, and 787-10 airplanes. The NPRM was
published in the Federal Register on March 13, 2026 (91 FR 12312). The
NPRM was prompted by 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. In the NPRM, the FAA proposed to require, depending on
configuration, UT inspections at certain splice plates, rear spar
terminal fittings, lower chords, front spar terminal fittings, and jack
pads for any cracks; repetitive DET of certain splice plates for any
cracks; and applicable on-condition actions. 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.
Discussion of Final Airworthiness Directive
Comments
United Airlines commented that it had no objections to the proposed
rule.
The FAA received additional comments from American Airlines (AAL)
and The Foundation for Aviation Safety. The following presents those
comments and the FAA's response.
Request for Simplified Compliance Time
AAL requested that the FAA revise the proposed AD to allow
simplified compliance time tracking for the initial and repetitive
inspections for all tasks, such as by allowing the use of only total
flight hours (TFH)/total flight cycles (TFC) for the initial
inspections and only flight hours (FH)/flight cycles (FC) for the
repetitive inspections. AAL stated that the compliance times specified
in Boeing Alert Requirements Bulletin B787-81205-SB570048-00 RB, Issue
001, dated August 11, 2025, require the use of an equation based on a
combination of TFH and TFC to determine the initial inspection
compliance time, and an equation based on the initial inspection and a
combination of FH and FC to determine the repetitive inspection
compliance times. AAL noted that the use of an equation for the initial
and repetitive inspections places a burden on the airline as its
internal tracking system does not support equation-based compliance
times, therefore requiring either manual tracking of the required
inspections for the life of the aircraft or choosing a conservative
hours or cycles limit that the airline stated would greatly reduce the
airplane yield between inspections.
The FAA disagrees with the request. The affected splice plates are
flight-length sensitive. The equation-based compliance times account
for the effects of both flight hours and flight cycles and are
relieving in nature compared to compliance times based solely on TFH/
TFC or FH/FC limits. Allowing the requested ``simplified'' compliance
time tracking would therefore be more burdensome for operators, and
many airplanes could become immediately out of compliance. The FAA has
not changed this AD as a result of this comment.
Question on Holding Boeing Accountable for Manufacturing Quality
Defects
The Foundation for Aviation Safety asked what the FAA is doing to
hold Boeing accountable for ongoing manufacturing quality defects. The
question did not request a change to this AD, and the FAA has not
changed the AD as a result.
Revision to Material Citations
In the NPRM, the material citations inadvertently did not include
``-00'' as part of the bulletin number. The full citations are Boeing
Alert Requirements Bulletin B787-81205-SB570048-00 RB, Issue 001, dated
August 11, 2025; and Boeing Alert Service Bulletin B787-81205-SB570048-
00, Issue 001, dated August 11, 2025. The FAA has revised this AD
accordingly.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, and
any other changes described previously, this AD is adopted as proposed
in the NPRM. None of the changes will increase the economic burden on
any operator.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin B787-81205-
SB570048-00 RB, Issue 001, dated August 11, 2025. This material
specifies procedures for performing repetitive UT inspections,
depending on configuration, 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.
Costs of Compliance
The FAA estimates that this AD affects 17 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
[[Page 55249]]
Estimated Costs
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Cost on U.S.
Action Labor cost Parts cost Cost per product operators
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UT and DET inspections........... Up to 286 work $0 Up to $24,310 per Up to $413,270 per
hours x $85 per inspection cycle. inspection cycle
hour = $24,310 per
inspection cycle.
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The FAA has received no definitive data on which to base the cost
estimates for the on-condition repairs specified in this 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 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
This AD will not have federalism implications under Executive Order
13132. This AD will 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 that this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Will not affect intrastate aviation in Alaska, and
(3) Will 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 Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
0
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
2026-17-02 The Boeing Company: Amendment 39-23445; Docket No. FAA-
2026-2295; Project Identifier AD-2025-01361-T.
(a) Effective Date
This airworthiness directive (AD) is effective October 1, 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-SB570048-00 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.
(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-SB570048-00 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-SB570048-00 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-SB570048-00, Issue 001, dated August 11, 2025, which is
referred to in Boeing Alert Requirements Bulletin B787-81205-
SB570048-00 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-SB570048-00 RB, Issue 001, dated August 11, 2025, refer to the
Issue 001 date of the Requirements Bulletin B787-81205-SB570048-00
RB, this AD requires using the effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin B787-81205-
SB570048-00 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)(1) of this AD. Information may be emailed to:
<a href="/cdn-cgi/l/email-protection#df9e92909c9fb9bebef1b8b0a9"><span class="__cf_email__" data-cfemail="90d1dddfd3d0f6f1f1bef7ffe6">[email protected]</span></a>. Before using any approved AMOC, notify your
appropriate principal inspector,
[[Page 55250]]
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: <a href="/cdn-cgi/l/email-protection#7d17120e180d155317531512191a14133d1b1c1c531a120b"><span class="__cf_email__" data-cfemail="076d687462776f296d296f6863606e694761666629606871">[email protected]</span></a>.
(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-SB570048-00
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 <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
(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 <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#c8aebae6a1a6bbb8adabbca1a7a688a6a9baa9e6afa7be"><span class="__cf_email__" data-cfemail="482e3a6621263b382d2b3c2127260826293a29662f273e">[email protected]</span></a>.
Issued on August 13, 2026.
Brian Knaup,
Acting Deputy Director, Integrated Certificate Management Division,
Aircraft Certification Service.
[FR Doc. 2026-17553 Filed 8-26-26; 8:45 am]
BILLING CODE 4910-13-P
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