FAA Orders Inspections of 119 Boeing 787s Over Faulty Oxygen Masks

The Federal Aviation Administration (FAA) is set to issue a final rule requiring U.S. airlines to inspect more than 100 Boeing 787 Dreamliners after discovering that some passenger oxygen masks may be faulty and could fail during a depressurization emergency.

According to a preview of the unpublished rule, 119 Boeing 787s operated by U.S. carriers will need inspections because oxygen supply tubing on certain masks may be kinked, creating what the FAA calls an “unsafe condition” that could lead to passenger injury. One of the affected aircraft includes an American Airlines Dreamliner slated for inspection to ensure all passenger oxygen masks function properly.

Before issuing the airworthiness directive, the FAA consulted affected airlines, Boeing, and other stakeholders on how best to resolve the problem. American Airlines requested the agency extend the compliance period from the originally proposed 24 months to 48 months. The FAA rejected that request but agreed to a 36-month timeframe to allow inspections and repairs during routine maintenance, reducing the need for unscheduled groundings.

The FAA notes that only a small number of oxygen masks may be affected, with the kinked tubing reported only in specific center-seat units. Regulators have now authorized airlines to remove the entire oxygen panel in affected units and replace it with new panels rather than attempt repairs on the existing assemblies.

As airworthiness directives go, this one is expected to be relatively inexpensive for U.S. carriers. The FAA estimates the total cost to inspect the planes at about $252,875.

This latest directive follows another FAA order in August 2024 requiring airlines to inspect potentially faulty pilot seat switches on Boeing 787s. That issue was linked to the sudden nosedive of a LATAM Airlines Dreamliner flying from Sydney to Auckland in March, which injured more than 50 passengers. Investigators found that a damaged cover on an electronic switch at the back of the captain’s seat jammed the rocker switch into motion when a flight attendant entered the cockpit, pinning the pilot against the control console and causing the plane to pitch downward.

The FAA determined the faulty switch cover was not isolated to a single aircraft and quickly mandated inspections and replacements across all U.S.-operated 787s. Unlike the new oxygen mask rule, the seat switch directive was issued without a public comment period due to the urgency of the situation.

With two airworthiness directives in as many years, the FAA’s actions highlight continued safety vigilance over the Boeing 787 Dreamliner fleet, ensuring that critical systems such as oxygen masks and pilot seats function properly to protect passengers and crew.


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Sources: AirGuide Business airguide.info, bing.com, paddleyourownkanoo.com