The Federal Aviation Administration (FAA) has issued an airworthiness directive (AD) regarding insulation issues identified in Boeing 767-300F cargo aircraft. The FAA stated that this issue could increase the risk of fire and smoke, and has ordered operators to replace the cargo compartment’s insulation covers.
Fire and Smoke May Spread to the Cabin
The FAA found that insulation covers in the cargo compartments of certain Boeing 767-300F aircraft could allow smoke to seep into the cabin through the sidewall panels. According to the FAA’s Notice of Proposed Rulemaking (NPRM), if this problem is not addressed, a fire could break out in the bilge area of the cargo hold, posing a risk of both fire and smoke in the passenger cabin.
Affected Aircraft and Compliance Deadline
A total of 32 Boeing 767-300F aircraft in the U.S. are affected by this directive. Operators will have a 36-month compliance period starting from the directive’s effective date of January 13, 2025, to replace the insulation covers.
The FAA estimates that replacing the insulation blankets will take approximately 270 labor hours and cost up to $58,850 in total. This estimate includes labor rates and parts costs, though some expenses may be covered under warranty, according to the regulator.
FAA and Industry Feedback
The FAA’s proposal has been supported without revisions by the Air Line Pilots Association (ALPA). However, Boeing, Aviation Partners Boeing (APB), and All Nippon Airways (ANA) requested the inclusion of alternative methods of compliance (AMOC).
After evaluating these AMOC requests, the FAA incorporated them into the final directive. The March 12, 2024, FAA AMOC letter was approved as an alternative method for complying with the directive’s requirements.
Cabin Smoke Incidents
The FAA’s new directive gained additional attention following recent incidents. For example, a United Airlines Boeing 767-400 passenger aircraft had to make an emergency landing in St. John’s, Newfoundland, after smoke was detected in the cabin.
Boeing 767-300F Deliveries and Future Outlook
Despite strikes and production disruptions, Boeing has continued delivering cargo aircraft. FedEx recently received a Boeing 767F, registered as N255FE, on October 23, with another aircraft, N254FE, expected to join its fleet soon.
However, Boeing announced earlier this year that 767F production would end in 2027, a decision linked to delays with the 777X model and shifting industry needs. Nevertheless, the production of the 767-based KC-46A Pegasus tanker will continue.
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