Key Takeaways:
(P1) National Transportation Safety Board officials are questioning why a series of structural failures on MD-11 aircraft over several decades were not communicated effectively, a line of inquiry central to the investigation of a fatal UPS crash that killed 15 people in November 2025. The hearing, which began May 19, focuses on why known fatigue cracks in an engine pylon bearing did not lead to broader regulatory action.
(P2) "Had we known more, we could have done more," Shannon Deckard, a UPS witness, said during the NTSB hearing, highlighting the communication gaps between the airline, manufacturer Boeing, and the Federal Aviation Administration.
(P3) The NTSB's preliminary report found that the left engine of UPS Flight 2976 detached during takeoff due to fatigue cracks in a pylon bearing. Testimony on May 19 revealed at least 10 prior instances of similar fractures on MD-11s since 1990. However, only four were reported to the FAA, raising questions about reporting requirements and definitions of critical structural elements. Following the crash, UPS inspected its MD-11 fleet and found three additional aircraft with the same defect.
(P4) The investigation puts a spotlight on the FAA's oversight and Boeing's historical safety reporting for the MD-11, an aircraft model it acquired through its merger with McDonnell Douglas. The outcome could lead to significant new airworthiness directives and changes in how maintenance and service issues are reported across the industry. The NTSB's final report, expected in 18 to 24 months, will determine probable cause and issue safety recommendations.
The May 19 hearing detailed a history of miscommunication and misunderstood risk surrounding the MD-11's engine pylon assembly. Investigators focused on a spherical bearing that connects the engine to the wing. When this bearing cracks from fatigue, it can shift and place abnormal stress on surrounding structures, leading to catastrophic failure.
Danny Wuo of the FAA testified that a service difficulty report should have been filed for every instance of a fractured bearing. However, confusion over whether the part was a "principal structural element" may have led to underreporting. Boeing had analyzed nine previous reports of bearing issues but determined they did not pose a critical safety risk. "There was a misunderstanding initially, 20 years ago, about the severity of the event that might result from failure of this bearing," said FAA's Melanie Violette.
The aircraft that crashed, N259UP, was a last-minute substitute for the flight to Hawaii. The originally scheduled plane was grounded after a crew member discovered a fuel leak during a pre-flight inspection, according to NTSB documents.
The crash and subsequent findings have already had major repercussions. UPS grounded its MD-11 fleet three days after the crash, and the FAA followed with a nationwide grounding the next day. In January 2026, UPS announced the permanent retirement of all its MD-11s, accelerating a previously planned phase-out.
While the FAA approved a return-to-service protocol for the aircraft type last week, allowing carriers like FedEx to resume flights after inspections, the long-term future of the aging fleet is in question. U.S. Rep. Morgan McGarvey of Louisville has called for the permanent grounding of all MD-11s.
The NTSB hearing will continue on May 20, focusing on the pylon's design requirements. The board's final recommendations could reshape maintenance protocols and regulatory oversight for the entire aviation industry, particularly concerning legacy aircraft.
This article is for informational purposes only and does not constitute investment advice.
