After the unexpected demise of two Boeing whistleblowers this year, the Federal Aviation Administration (FAA) disclosed that at least 300 planes of the world’s largest aerospace company have a potentially lethal flaw that could cause the entire aircraft to explode mid-air.
The aircraft maker found that Boeing 777 liners have fragile electrical insulation around their fuel tanks, as per a proposed rule the FFA posted in March.
“This condition, if not addressed, could result in an ignition source inside the fuel tank and subsequent fire or explosion,” the Airworthiness Directives stated.
The FAA reported the issue in March and sought feedback from Boeing and other independent experts by May 9, although it is still uncertain whether the company responded.
The potential lethal flaw would affect nearly 300 Boeing aircraft in the United States
Speaking to Daily Mail, a Boeing representative emphasized that the FAA’s March 25, 2024, notice was for a “proposed rulemaking,” requesting input from scandal-hit firm Boeing and others before the FAA formally mandated any planned modifications to its 777 series of planes.
This is one of the most significant safety warnings issued by regulators to Boeing following several incidents where passenger jets experienced door plug blowouts, mid-air engine fires, and two fatal crashes that claimed the lives of 346 people.
The potential lethal flaw would affect nearly 300 Boeing aircraft in the United States, including the 77-200, -200LR, -300, -300ER, and 777F series jets. After Boeing informed the FAA about the defect, the federal authority proposed a solution that would cost $14 million to repair all 292 susceptible US-registered aircraft.
“The proposed AD, which the FAA issued in March 2024, would require installing electrical bonding and grounding to a component in the center fuel tank. It would make mandatory service actions that Boeing described in a November 2023 alert bulletin,” an FAA representative said in a statement.
According to the proposal, each aircraft would be inspected for approximately 90 hours before the installation of Teflon sleeves and cap fasteners in specific sections of the main fuel tanks. If implemented, Boeing would need 60 months to complete the modifications, suggesting that the vulnerability is not an immediate issue.
“We are aware of the FAA’s notice of proposed rulemaking and had previously issued guidance to 777 operators on this,” Boeing told Bloomberg.
The company further added that it fully supports the FAA’s recommendations to make that guidance mandatory. In a Senate testimony last month, whistleblower Sam Salehpour asserted that there is no safety culture at Boeing. He accused the company’s workers of using incorrect and unproven methods to align parts on the 777.
Salehpour claimed that he was “ignored” and told “to shut up” after he reported the issue to the authorities. Meanwhile, a Boeing spokesperson told The Post that this is not an immediate safety problem for flights.
“There are multiple redundancies designed into modern commercial airplanes to ensure protection against electromagnetic effects.” The 777 fleet has been flying for nearly three decades and has safely transported over 3.9 billion people, the representative added. Boeing has been facing criticism for various faults with its aircraft, including a door stopper that blew out during an Alaska Airlines trip in January.
