Cargo aircraft of the same model involved in a fatal Kentucky accident last autumn have been cleared to fly again after federal regulators approved safety modifications over the weekend.
Federal Aviation Administration officials announced they had given the green light to Boeing’s proposed repairs for the MD-11 aircraft “after extensive review.” FedEx immediately began operating the planes for package delivery services on Sunday.
The November 2025 UPS accident occurred when the aircraft’s left engine separated from the wing during takeoff at Louisville’s Muhammad Ali International Airport. The incident claimed the lives of three crew members aboard the Hawaii-bound cargo flight, along with 12 individuals on the ground.
Boeing’s solution involved replacing a critical spherical bearing component and increasing inspection frequency for engine mounting hardware. The National Transportation Safety Board revealed that Boeing had recorded four similar bearing failures on three different MD-11 aircraft in 2011, though the manufacturer concluded at that time it would not create “a safety of flight condition.” McDonnell Douglas originally manufactured these planes before Boeing acquired the company.
Following the crash, aviation authorities grounded the entire MD-11 fleet due to safety concerns. UPS responded by retiring all of its MD-11 aircraft earlier this year, representing roughly 9% of the company’s total fleet. FedEx, however, maintained its commitment to returning the planes to operation despite them comprising only about 4% of its aircraft. Western Global Airlines, the third carrier operating MD-11s, has remained silent since the incident and did not respond to requests for comment regarding the FAA’s decision.
In a company statement, FedEx detailed its collaboration with Boeing, federal regulators, and internal specialists to examine and modify its aircraft, with government certification confirming compliance with Boeing’s guidelines. The company operates 46 of these planes, though more than two dozen were already in storage before the accident occurred.
“Safety is our highest priority at FedEx,” the company said.
Despite the return to service, FedEx intends to phase out its MD-11 fleet in favor of more fuel-efficient aircraft, a strategy announced prior to the Louisville crash.
Legal representatives for families pursuing lawsuits related to the Louisville accident expressed cautious optimism about the safety measures.
“We hope the FAA does a thorough job of investigating the fixes before the MD-11 fleet is allowed to return to flight,” lawyer Bradley Cosgrove said.
Aviation safety specialist Jeff Guzzetti expressed surprise at the lengthy grounding period, considering the NTSB’s rapid identification of probable causes for the engine separation. The NTSB has scheduled two days of investigative hearings next week to examine the crash in greater detail.
“I’m confident that the solution will work, and I would like to see the MD-11s back up in the air. It will be a safe airplane with regards to its engines after these corrective actions are made,” said Guzzetti, who used to investigate crashes for both the NTSB and FAA.
Industry analysts had questioned whether MD-11s would ever return to service if repair costs exceeded the economic value of the aging aircraft. However, Boeing successfully addressed safety issues through bearing replacement and enhanced inspection protocols.
