FAA Orders Urgent Inspections for Boeing 757 Scimitar Winglets
Aviation News Editor & Industry Analyst delivering clear coverage for a worldwide audience.
The FAA has issued an urgent directive for Boeing 757s with scimitar winglets after cracks were found on five aircraft, affecting 156 U.S. jets.
Key Takeaways
- •Mandates urgent inspections on 156 U.S.-registered Boeing 757 aircraft.
- •Requires High Frequency Eddy Current checks for cracks in a modified wing skin area.
- •Addresses a critical safety risk of reduced structural integrity and potential wing loss.
- •Follows the discovery of similar cracks on five separate 757 aircraft.
The Federal Aviation Administration (FAA) has issued an urgent Airworthiness Directive (AD) requiring immediate inspections of certain Boeing 757 aircraft equipped with Scimitar Blended Winglets. The mandate follows the discovery of cracks on five separate aircraft, prompting concerns about the structural integrity of the modified wing structure. The directive affects an estimated 156 U.S.-registered Boeing 757-200 and 757-300 series aircraft.
The FAA's action, detailed in AD 2026-04-06, creates a legally enforceable requirement for operators to conduct inspections within five days of the directive's effective date of February 26, 2026. The regulator stated that the unsafe condition, if not addressed, could lead to "reduced structural integrity or partial wing loss leading to loss of control of the airplane." In a parallel move, the European Union Aviation Safety Agency (EASA) adopted the FAA's directive on February 27, 2026, extending the inspection requirement to operators under its jurisdiction.
Directive Details and Crack Findings
According to the FAA directive, the issue originated with the discovery of a crack on a Boeing 757-200 during a scheduled heavy maintenance check. Following this initial finding, operators reported four additional instances of similar cracks to the FAA in February 2026. All five cracks were located in the inspar outer lower wing skin area, specifically near access panel 543BB.
The affected component is not part of the original Boeing 757 airframe but is a skin panel installed during the aftermarket modification to add Scimitar Blended Winglets (SBW). These winglets are designed, manufactured, and installed by Aviation Partners Boeing (APB), a joint venture between Aviation Partners Inc. and The Boeing Company. The SBW modification is a popular retrofit for the 757 fleet, designed to improve fuel efficiency on the aging airframes.
The required inspection calls for a specific High Frequency Eddy Current (HFEC) examination of the affected area. HFEC is a non-destructive testing method used to detect surface and near-surface flaws in metallic parts. If cracks are found during the inspection, the AD mandates that repairs must be performed using a method approved by the FAA before the aircraft can be returned to service.
In a statement, The Boeing Company expressed its support for the regulatory action. "We support the FAA's airworthiness directive, which makes mandatory the inspection guidance Boeing provided 757 operators with scimitar blended winglets," the company stated.
Regulatory Urgency and Fleet Context
The FAA's five-day compliance window underscores the seriousness of the potential safety risk. This timeframe is significantly shorter than the 30-day period originally recommended in an Alert Service Letter (APBSL757-0039 Rev IR) issued by Aviation Partners Boeing on February 4, 2026. The FAA determined that the risk of wing structure failure necessitated a more accelerated inspection schedule.
The Boeing 757, a workhorse for many passenger and cargo airlines, ceased production in October 2004 after 1,050 aircraft were built. A significant portion of the global fleet remains in active service, making aftermarket modifications like the APB winglets critical for extending their operational life and improving economic viability through fuel savings.
This AD highlights a recurring challenge in the aviation industry: ensuring the long-term structural integrity of aging aircraft, particularly those with significant third-party modifications. While such modifications are certified as safe upon installation, unforeseen stress and fatigue issues can emerge over years of service. Regulatory bodies like the FAA and EASA rely on a combination of manufacturer service bulletins, operator reports, and in-service data to identify and mitigate these emerging risks.
Operators of the affected Boeing 757 aircraft must now arrange for the specialized HFEC inspections to be completed under the compressed timeline, which could cause short-term operational disruptions depending on maintenance slot availability and the number of affected aircraft in an airline's fleet.
Why This Matters
This directive underscores the regulatory vigilance required to manage an aging global fleet. It demonstrates how aftermarket modifications, while beneficial for performance, can introduce novel structural fatigue points that require specific, targeted inspections beyond the original manufacturer's maintenance program. For operators, it reinforces the total lifecycle costs and maintenance complexities associated with extending the service of older airframes.
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Written by Ujjwal Sukhwani
Aviation News Editor & Industry Analyst delivering clear coverage for a worldwide audience. Covers flight operations, safety regulations, and market trends with expert analysis.
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