Unexpected Cracking Found on Critical Boeing 737 Next-Gen Part

Boeing engineers and safety investigators are scrambling to find out how many Boeing 737NGs have cracked 'pickle forks' after finding several in the jets.

A pickle fork is the part that helps attach a plane's fuselage to its wing structure. It helps manage the stress, torque and aerodynamic forces that bend the connection between the wings and the body of the jet.

Engineers design pickle forks to last the lifetime of the plane, more than 90,000 landings and takeoffs, a term known as "flight cycles" in the aviation industry, without developing cracks. There could be dire results if the pickle fork system on the jet fails in flight.

During a recent inspection, workers found a severely cracked pickle fork on a Boeing 737NG. The plane is relatively young, having logged approximately 35,000 flight cycles when the damage was found.

A retired Boeing engineer who asked to remain anonymous tells us, "It's unusual to have a crack in the pickle fork. It's not designed to crack that way at all. Period." He says it's particularly concerning because it was found so early in the plane's service.

Another source tells us Boeing quickly reported the issue with the single plane to the FAA last week, and now more planes with similar cracking have been found.

We're told this is very much an ongoing investigation, and that it's unclear whether or not this is a widespread issue.

Boeing confirmed to KOMO Friday that there is a cracking issue.

"Safety and quality are our top priorities. Boeing has notified the FAA and been in contact with 737NG operators about a cracking issue discovered on a small number of airplanes undergoing modifications. No in-service issues have been reported. Over the coming days, we will work closely with our customers to implement a recommended inspection plan for certain airplanes in the fleet. This issue does not affect any 737 MAX airplanes or the P-8 Poseidon," a Boeing spokesperson wrote. (end of excerpt)

Click here for the full story, on the Komo News website.

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