FAA Orders Inspections of Boeing 787 Fuel Tank Sealant
A new airworthiness directive requires U.S. operators of certain 787 aircraft to inspect fuel tank sealant installations starting December 7.
Updated on Nov. 2, 2026 in Air Travel
The Federal Aviation Administration issued an airworthiness directive on Monday requiring inspections of fuel tank sealant on certain Boeing 787-8, 787-9, and 787-10 aircraft. The sealant installations lacked Boeing documentation confirming required visual and adhesion inspections during manufacturing.
Why it matters
The unsafe condition, if not addressed, could create an ignition source within the fuel tank and a risk of fuel tank explosion during a lightning strike. Because the required production inspections could not be verified, the FAA is requiring operators to check the work directly.
The FAA estimates 60 U.S.-registered aircraft are affected, with inspections taking about 34 work-hours and costing roughly $2,890 per airplane, or $173,400 across the fleet. These figures exclude any repairs, for which the agency said it lacked sufficient cost data.
The players
Federal Aviation Administration
The Federal Aviation Administration is the U.S. federal agency responsible for regulating civil aviation and ensuring the airworthiness of aircraft operating in the United States.
Boeing
Boeing is a major American aerospace manufacturer and the producer of the 787 Dreamliner and 737 MAX aircraft.
The details
Operators must examine sealant installations in the left, right, and center wing side-of-body areas, conduct adhesion tests, and complete necessary repairs. The FAA accepted Boeing's proposal to permit repairs performed under specified airworthiness limitations and clarified the required adhesion testing locations.
Timeline
Monday, November 2: The FAA issued the airworthiness directive.
December 7: The directive takes effect.
July: The FAA restored Boeing's authority to issue airworthiness certificates for newly produced 787 and 737 MAX aircraft.
Seasonal Patterns
The directive follows the FAA's July restoration of Boeing's authority to issue airworthiness certificates for 787 and 737 MAX aircraft. It shows the agency continuing to scrutinize Boeing's production documentation even after returning that certification authority.
Travelers flying on affected 787-8, 787-9, or 787-10 aircraft may see those planes temporarily taken out of service while operators complete the inspections. Airlines may need to adjust schedules, and some repair costs may be covered under Boeing's warranty.
The takeaway
The directive shows regulators verifying safety documentation directly when manufacturer records fall short. Air travelers can expect aircraft safety rules to be enforced through inspections even after a manufacturer's certification authority has been restored.
What happens next
Operators of affected 787 aircraft must complete the sealant inspections, adhesion tests, and any necessary repairs once the directive takes effect on December 7.
Further reading
For broader context on aircraft safety oversight, see the Air Travel section.
Source note: This article includes information reported by AVweb.
