FAA Orders Urgent Inspections of MD-11 Engine Pylons After Deadly UPS Crash

The Federal Aviation Administration (FAA) has issued an emergency airworthiness directive (AD) requiring immediate inspections of all McDonnell Douglas MD-11 aircraft before further flight. The order follows the fatal November 4 crash of a UPS MD-11 in Louisville, Kentucky, and reinforces Boeing’s earlier recommendation that operators ground their fleets as a precaution while investigators determine the cause of the accident.

The directive, released late on November 8, specifically targets the aircraft’s engine pylons but provides few technical details. It prohibits any MD-11 operations “until the airplane is inspected and all applicable corrective actions are performed using a method approved by the FAA.” The agency said the order “was prompted by an accident where the left-hand engine and pylon detached from the airplane during takeoff.” The cause of the detachment remains under investigation.

Boeing and Airlines React

Boeing, which acquired McDonnell Douglas in 1997, recommended on November 7 that all MD-11 freighters be voluntarily grounded “out of an abundance of caution.” “With safety as our top priority, we recommended to the three operators of the MD-11 Freighter that they suspend flight operations while additional engineering analysis is performed,” the company said in a statement. Boeing later confirmed its full support for the FAA’s directive and pledged ongoing coordination with regulators and operators.

UPS and FedEx promptly complied with Boeing’s recommendation, grounding their entire MD-11 fleets. The third operator, Western Global Airlines, did not immediately respond to inquiries. Boeing did not specify what prompted its decision but emphasized that it was working closely with the FAA and the National Transportation Safety Board (NTSB).

Details of the UPS MD-11 Accident

The accident aircraft, operating as UPS Flight 2976, suffered a catastrophic failure during its takeoff roll from Runway 17R at Louisville Muhammad Ali International Airport. According to preliminary reports, the left (No. 1) GE Aerospace CF6-80C2 engine and most of its pylon separated from the wing as the jet accelerated for departure. Video footage showed flames streaming from the inboard section of the left wing where engine No. 1 was mounted, with possible secondary damage observed near engine No. 3, mounted on the right wing.

The aircraft briefly became airborne, clearing the airport perimeter before crashing in an industrial area less than half a nautical mile from the runway’s end, triggering a massive fire. All three pilots onboard were killed, along with eleven others on the ground. In total, 14 fatalities have been confirmed.

Early Investigation Focus

NTSB investigators are examining whether the initial failure originated within the engine itself or if a structural problem in the pylon caused the separation. It remains unclear if the other two engines were damaged or contributed to the sequence of events. Investigators plan to conduct simulator testing to model multiple failure scenarios. “We’re looking at all possibilities,” NTSB Member Todd Inman said during a November 7 briefing.

The global MD-11 fleet operates with two engine types—the GE CF6-80C2 and the Pratt & Whitney PW4000. Since the FAA directive applies to all variants, safety experts believe the concern extends beyond a single engine type. Boeing engineers are assisting investigators in analyzing the wreckage and engine components recovered from the crash site.

Global Fleet Grounded

As of late 2025, there are approximately 40 to 50 McDonnell Douglas MD-11 aircraft still active in service, all operating as freighters. According to Aviation Week’s Fleet Discovery database, 59 MD-11s are currently active or recently parked, with an additional 10 in storage. The operational fleet includes 29 aircraft at FedEx, 25 at UPS, and five at Western Global Airlines. Several aircraft had already been parked for more than 30 days before the grounding.

The emergency inspections mark the most serious regulatory action involving the MD-11 in decades. While the tri-jet has been a dependable workhorse in global cargo operations, the Louisville accident—and subsequent grounding—has renewed scrutiny over the aging aircraft’s structural integrity.

As investigators work to identify the root cause, both the FAA and Boeing have emphasized that safety remains their top priority. The findings from this investigation could shape not only the future of the MD-11 but also broader maintenance and inspection standards for aging freighter aircraft across the industry.

Sources: AirGuide Business airguide.info, bing.com, ups.com, aviationweek.com