The Federal Aviation Administration (FAA) has issued a new airworthiness directive requiring additional inspections of certain Boeing 787 Dreamliner aircraft. The directive follows the identification of deficiencies in manufacturing quality control records and inspections involving sealant installations inside the center wing fuel tank, raising concerns about a potential safety hazard under certain circumstances.

Published on November 2, 2026, the directive takes effect on December 7 and applies to selected aircraft across all three Dreamliner variants, the 787-8, 787-9 and 787-10. The FAA estimates that approximately 60 US-registered aircraft are affected, while the total number of potentially impacted aircraft worldwide has not been specified.

According to FAA documentation, required visual inspections and sealant adhesion tests were either not performed or could not be adequately verified during production in certain areas of the center wing fuel tank. Sealants play an important role in protecting fuel tank structures, including preventing the development of potential ignition sources. Improper installation could create hazardous conditions in the event of a lightning strike.

The FAA warns that uncorrected deficiencies could, under the most adverse circumstances, allow an ignition source to develop inside the fuel tank, potentially igniting fuel vapors and causing an explosion. However, the directive addresses identified manufacturing quality control deficiencies and a potential safety risk, rather than any reported explosion or accident associated with the condition.

Airlines and other operators of affected aircraft will be required to carry out detailed inspections of sealant installations in the left, right and center wing side-of-body areas, including sections between the relevant structural ribs. Inspections will focus on identifying possible damage, surface depressions and inadequate sealant adhesion. The work must follow Boeing’s technical requirements bulletin issued on November 5, 2025, which specifies the necessary inspection and testing procedures. Any discrepancies discovered will have to be corrected using approved repair methods.

According to FAA estimates, the inspections and adhesion tests will require approximately 34 labor hours per aircraft. The estimated cost is $2,890 per aircraft, bringing the total to $173,400 for the 60 affected US-registered aircraft. These figures exclude any additional repairs, the cost of which remains undetermined. Some expenses may be covered under Boeing’s warranty.

The final directive follows a consultation process initiated in February 2026, during which Boeing and American Airlines requested clarification of several technical requirements. Boeing proposed allowing certain sealant repairs to be performed using existing approved maintenance procedures instead of requiring separate approval for each repair. The FAA accepted this approach, subject to compliance with applicable technical requirements. American Airlines also requested a more precise definition of the areas requiring adhesion testing, which the FAA subsequently clarified in the final documentation.

During the consultation period, the Foundation for Aviation Safety separately requested confirmation that the required inspections were being performed during current aircraft production. The FAA responded that the necessary sealant inspections are now being conducted on aircraft outside the scope of the new directive.

As reported by AeroTime, the directive is primarily intended to address potential consequences of inadequately documented manufacturing inspections on previously produced aircraft. Operators must verify the actual condition of the affected structures and correct any deficiencies within the timeframes established by the applicable technical documentation.