Boeing’s troubled 777X program has suffered another major blow: a cracked component was discovered, forcing the company to halt flight testing. The problem, discovered during routine maintenance on a 777-9 aircraft, affects a thrust link that connects the engine to the wing.
Worse still, the latest setback exacerbates delays in the already long-delayed 777X program and could push the schedule back even further.
Structural failure in engine mounts
(Photo: Boeing)
When Boeing discovered a crack in a structural component of the 777X aircraft, the company decided to suspend flight tests. This could delay the delivery of the jets.
As first reported by The Air Current, the problem was discovered during routine maintenance on a 777-9 aircraft that found a cracked thrust link, a critical component that connects General Electric’s engines to the plane’s wings.
Boeing has informed the Federal Aviation Administration (FAA) of the situation and provided details to its customers.
The company is currently reviewing the rest of its test fleet for similar issues, although no immediate flight tests are planned for the other aircraft currently undergoing maintenance.
“Our team is replacing the part and capturing all the lessons we learn from the component and will resume flight testing when it is ready,” Boeing said in a statement.
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Impact on 777X certification and schedule
The discovery of the structural defect is a major blow to Boeing’s efforts to certify the 777X, which is already five years behind schedule. Boeing began flight tests involving the U.S. Federal Aviation Administration in July, a key milestone in the certification process, but this latest problem could delay the program even further.
Emirates, one of Boeing’s largest customers, expects to receive its first 777X aircraft by 2026, with full certification scheduled for late 2025. But that timeline may now be in jeopardy.
Reactions from industry and customers
According to Linus Bauer, founder of aviation consulting firm BAA & Partners, the suspension of flight testing could have a significant impact on Boeing’s 777X program.
Bauer called the certification process a “critical phase” and such a disruption could lead to delays. He added that this latest setback could exacerbate Boeing’s existing challenges, especially since the 777X is a cornerstone of the company’s long-term strategy for the wide-body jet market.
Emirates and Qatar Airways, two of the 777X’s largest customers, are closely monitoring the situation. Qatar Airways recently increased its order for the 777X family, bringing its total order to 94 aircraft. Further delays could strain Boeing’s relationships with these important customers and affect its market position.
Additional challenges: 787 Dreamliner inspections
Adding to Boeing’s woes, the FAA has issued an airworthiness directive requiring inspections of the cockpit seats on Boeing’s 787 Dreamliners following reports of unprompted seat movements that have caused flight disruptions.
In an incident in March 2024, a Latam Airlines Boeing 787 suddenly nosedived in mid-air, injuring over 50 passengers.
The FAA’s policy requires airlines operating Boeing 787-8, 787-9 and 787-10 aircraft to inspect the seat switches responsible for controlling seat movement.
While Boeing has expressed its full support for the FAA’s order, the additional inspections are likely to be frustrating for customers and costly for the company.
New leadership faces a tough 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 took office on August 8, has promised to “restore confidence” in Boeing, a task that is becoming increasingly difficult in light of these setbacks.
Bauer noted that further delays to high-profile programs like the 777X could undermine confidence in Boeing’s leadership and technical capabilities. Effectively addressing these issues will be critical for Ortberg as he works to restore stakeholder confidence and secure Boeing’s future in the global aviation industry.
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