The Federal Aviation Administration (FAA) has issued two airworthiness directives requiring inspections of fuel-tank components on 91 US-registered Boeing aircraft. The measures apply to 60 Boeing 787s and 31 Boeing 747s, with the requirements taking effect on 7 December 2026.
Airlines operating the affected aircraft must examine specified areas and complete repairs where defects are found. The regulator’s action follows concerns that conditions inside the fuel system could provide an ignition source during a lightning strike, creating a potential safety risk in a fuel-tank environment.
“If not addressed, could result in development of an ignition source within the fuel tank volume and a risk of a fuel tank explosion during a lightning strike event.” — Federal Aviation Administration
Checks required on selected 787s
The directive covering the Dreamliner concerns certain Boeing 787-8, 787-9 and 787-10 aircraft. The FAA said the issue relates to sealant applied inside the centre wing fuel tank, where required visual and adhesion checks were not completed during production on some aircraft.
Operators will have to inspect the sealant in the affected locations for defects, poor adhesion and surface depressions. Any necessary corrective work must then be carried out in accordance with the directive. The FAA estimates that the inspection will require approximately 34 work-hours per aircraft, at an estimated cost of about $2,890 per aircraft.
The regulator has stressed that the order is limited to a defined group of 787s rather than the aircraft family as a whole. It also said that the required production inspections are now being performed on 787s outside the directive’s scope.
Separate action covers Boeing 747 fuel pumps
The second directive applies to certain Boeing 747-400 and 747-8 aircraft. In this case, the FAA’s concern centres on pumps installed in the tail fuel tank. Wear within the pump assembly could expose metal surfaces, which the regulator said might create an ignition source when fuel vapour is present.
| Aircraft | Aircraft covered | Required action |
|---|---|---|
| Boeing 787-8, 787-9 and 787-10 | 60 US-registered aircraft | Inspect centre wing fuel-tank sealant and repair where required |
| Boeing 747-400 and 747-8 | 31 US-registered aircraft | Inspect specified tail fuel-tank pump components and complete necessary corrective work |
The FAA described the 747 action as a replacement for an earlier requirement involving a one-off inspection. Both directives will become effective on 7 December, giving operators time to schedule the work within their maintenance programmes before the compliance date.
- 60 US-registered Boeing 787s are included in the Dreamliner directive.
- 31 US-registered Boeing 747s are covered by the separate pump-related directive.
- The FAA says the 787 inspection will take about 34 work-hours per aircraft.
