Fatal Louisville Crash Accelerates UPS Retirement of McDonnell Douglas MD-11 Fleet

United Parcel Service (UPS) has permanently retired its entire McDonnell Douglas MD-11 cargo planes fleet.

The decision was announced by CEO Carol Tomé during a fourth-quarter earnings call. This move follows the fatal November 4, 2025, crash of a UPS MD-11 freighter in Louisville, Kentucky. The company stated it chose to "accelerate our plans and retire all MD-11 aircraft in our fleet."

The Louisville Crash and Investigation

The accident involved UPS Airlines Flight 2976, which crashed shortly after takeoff. The flight originated from Louisville Muhammad Ali International Airport (SDF). It was bound for Honolulu, Hawaii.

The crash tragically killed the plane's three-person crew and 12 people on the ground. The aircraft's left engine detached from the wing, causing the loss of control.

NTSB Preliminary Findings

Investigators from the National Transportation Safety Board (NTSB) found critical evidence. They discovered fatigue cracks in the parts holding the engine to the wing. These key engine mount parts, specifically the pylon's aft mount, had not been inspected since 2021. The fatigue cracking was a key factor in the engine separation.

Regulatory and Industry Impact

Following the accident, the Federal Aviation Administration (FAA) issued an Emergency Airworthiness Directive (EAD). This directive ordered the immediate FAA emergency grounding of all MD-11 and MD-11F aircraft. The FAA also extended the grounding to include the similar-design DC-10 and MD-10 models. The agency stated the unsafe condition was "likely to exist or develop" in other aircraft of the same type design. The FAA continues to review the facts before deciding on the aircraft's future airworthiness.

UPS's MD-11s accounted for about 9% of its total aircraft fleet. The UPS MD-11 fleet retirement resulted in a $137 million after-tax charge for the company. This charge was for writing off the retired aircraft.

Status of Other Operators

Two other major U.S. operators of the tri-jet freighter were also affected by the EAD. FedEx and Florida-based Western Global Airlines had their MD-11 fleets grounded in November. FedEx has indicated it expects its MD-11 fleet to return to service. Company officials project a return by their fourth quarter, ending May 31, 2026. This return is pending the completion of FAA-approved inspections and repairs. The grounding cost FedEx an estimated $175 million in lost capacity. Western Global Airlines has not yet provided a confirmed timeline for its MD-11s to fly again. The indefinite grounding led Western Global to furlough approximately 70 pilots.

Fleet Modernization and Future Capacity

UPS framed the retirement as an accelerated fleet modernization plan. The company is moving toward a more fuel-efficient, twin-engine fleet. To replace the lost capacity, UPS will take delivery of 18 new Boeing 767 freighters over the next 15 months. The Boeing 767 is a twin-engine widebody freighter. It offers better fuel efficiency and lower maintenance costs than the older tri-jet design.

During the recent peak holiday season, the grounding forced UPS to adjust its operations. The company leased additional planes and increased its ground transportation volume. It also brought in aircraft from other parts of the world to maintain service levels. UPS CEO Carol Tomé praised the Worldport team for their response to the disruption. She also thanked the Louisville community for its support.

This retirement marks a significant moment in U.S. air cargo logistics impact. It effectively removes the MD-11 from U.S. commercial cargo service for now. The future of the McDonnell Douglas MD-11 cargo planes now rests with the FAA and the decisions of FedEx and Western Global Airlines. The investigation into the MD-11 engine pylon cracks highlights the critical need for robust maintenance protocols on aging widebody aircraft. The final NTSB report will be crucial for global cargo aviation safety standards.

• The crash killed 15 people: three crew and twelve on the ground.
• NTSB found fatigue cracks in the engine pylon mount, last inspected in 2021.
• UPS incurred a $137 million charge to write off the MD-11 fleet.
• UPS will receive 18 new Boeing 767 freighters over the next 15 months to replace capacity.
• The FAA EAD remains in effect, grounding all U.S.-registered MD-11s, MD-10s, and DC-10s.

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