Boeing warned companies in 2011 about broken part that caused Louisville UPS plane crash

Boeing warned plane owners in 2011 about a broken part that contributed to a UPS plane crash that killed 15 last year but at that point the plane manufacturer didn’t believe it threatened safety, the National Transportation Safety Board said Wednesday.

The UPS plane crashed in November 2025 shortly after taking off in Louisville, Kentucky, when the left engine flew off the wing as the plane rolled down the runway. Three pilots on the plane that was headed for Hawaii were killed along with 12 more people on the ground near Louisville’s Muhammad Ali International Airport.

The NTSB said Wednesday that Boeing had documented in 2011 there were four previous failures of a part that helps secure the MD-11’s engines to the wings on three different planes, but at that point the plane manufacturer “determined it would not result in a safety of flight condition.” These planes were actually built by McDonnell Douglas, which was later bought by Boeing.

The NTSB previously said investigators found cracks in some of the parts that held the engine to the wing. Those cracks hadn’t been caught in regular maintenance done on the plane, which raised questions about the adequacy of the maintenance schedule. The last time those key engine mount parts were examined closely was in October 2021, and the plane wasn’t due for another detailed inspection for roughly 7,000 more takeoffs and landings.

It’s not clear when the cracks started to develop in the parts that helped hold the engine on the wing, but this crash is reminiscent of a 1979 crash in Chicago when the left engine flew off an American Airlines DC-10 during takeoff, killing 273 people. The DC-10 was the predecessor of the MD-11.

That previous crash led to the worldwide grounding of 274 DC-10s. The airline workhorse was allowed to return to the skies because the NTSB determined that maintenance workers damaged the plane that crashed while improperly using a forklift to reattach the engine. That meant the crash wasn’t caused by a fatal design flaw even though there had already been a number of accidents involving DC-10s.

But former FAA and NTSB crash investigator Jeff Guzzetti said that a service bulletin McDonnell Douglas issued in 1980 did identify failures of the spherical bearing race as a “safety of flight condition” so it’s surprising that Boeing didn’t call it that in 2011. He said that American had removed the engine of that plane so it could inspect that bearing.

The service bulletin that Boeing issued didn’t require plane owners to make repairs like an FAA airworthiness directive would, and the agency didn’t issue such a directive.

Former federal crash investigator Alan Diehl said the notice from Boeing recommended replacing the bearings with a redesigned part that was less likely to fail, but it still allowed operators to replace defective bearings with another older bearing that had demonstrated it was prone to failing.

“As the investigation continues, the NTSB will have to address whether this service bulletin was an adequate solution to a known problem which could have had catastrophic results,” Diehl said. “The UPS crash highlights the need for increased maintenance measures on older airframes.”

Photos released by the NTSB of the Nov. 4 crash show flames erupting as the rear of the engine starting to detach before it flew up and over the wing. Then the wing was engulfed by fire as the burning engine flew above it.

The report will undoubtedly be cited in the first lawsuit over the crash, filed last month, and subsequent ones. They will be investigating what Boeing knew at the time and what UPS did in response to this 2011 bulletin.


(AP Photo Jon Cherry)