Boeing's troubled 777X program has suffered another significant blow with the discovery of a cracked structural component, forcing the company to halt flight tests. The issue, found during routine maintenance on a 777-9 aircraft, involves a thrust link that connects the engine to the wing.
Even worse, the latest setback adds to the delays in the already long-delayed 777X program, potentially pushing its timeline further behind schedule.
Structural Failure in Engine Mounts
As initially reported by The Air Current, the issue was discovered during routine maintenance on a 777-9 aircraft, where a cracked thrust link was identified. This crucial component connects the General Electric engines to the aircraft's wings.
Boeing has informed the Federal Aviation Administration (FAA) about the situation and has shared details with its customers.
The company is now inspecting the rest of the flight test fleet for similar issues, although no immediate flight tests were scheduled for the other aircraft currently undergoing maintenance.
"Our team is replacing the part and capturing any learnings from the component and will resume flight testing when ready," Boeing said in a statement.
Impact on 777X Certification and Timeline
The discovery of the structural failure is a huge blow to Boeing's efforts to certify the 777X, a process that is already five years behind schedule. Boeing began flight tests with U.S. aviation regulators on board in July, marking a key milestone in the certification process. However, this latest issue could further delay the program.
Emirates, one of Boeing's largest customers, expects to receive its first 777X aircraft by 2026, with full certification anticipated by the end of 2025. However, this timeline may now be at risk.
Industry and Customer Reactions
The suspension of flight testing could have a substantial impact on Boeing's 777X program, according to Linus Bauer, founder of aviation consultancy BAA & Partners.
Bauer described the certification process as a "critical phase" and such interruption could result in delays. He added that this latest setback could exacerbate Boeing's existing challenges, particularly as the 777X is a cornerstone of the company's long-term strategy for the wide-body market.
Emirates and Qatar Airways, two of the largest customers for the 777X, are closely monitoring the situation. Qatar Airways recently expanded its order for the 777X family, bringing its total order to 94 aircraft. Any further delays could strain Boeing's relationships with these key clients and impact its market position.
Additional Challenges: 787 Dreamliner Inspections
Compounding Boeing's difficulties, the FAA has issued an airworthiness directive requiring inspections of the cockpit seats on Boeing's 787 Dreamliners. This directive follows reports of uncommanded seat movements that have disrupted flights.
In one incident in March 2024, a Latam Airlines 787 experienced a sudden mid-air dive, injuring over 50 passengers.
The FAA's directive mandates that airlines operating Boeing's 787-8, 787-9, and 787-10 models inspect the seat switches responsible for controlling seat movements.
Boeing has expressed full support for the FAA's directive, but the additional inspections will likely be frustrating for customers and costly for the company.
New Leadership Faces Uphill Battle
These challenges come at a critical time for Boeing, as the company's new CEO, Kelly Ortberg, has just taken the helm. Ortberg, who started his role on August 8, has pledged to "restore trust" in Boeing, a task that is becoming increasingly difficult in light of these setbacks.
Bauer noted that further delays in high-profile programs like the 777X could undermine confidence in Boeing's leadership and technical capabilities. Addressing these issues effectively will be crucial for Ortberg as he works to restore stakeholder confidence and secure Boeing's future in the global aviation industry.
