NTSB Focuses on Maintenance Procedures on First Day of UPS Crash Hearing

Maintenance procedures and protocols took center stage on day one of the National Transportation Safety Board’s hearing on the fatal crash of UPS Flight 2976. 

The two-day hearing in Washington, D.C., is an information-gathering exercise, with Boeing, UPS, ST Engineering, Independent Pilots Association, Teamsters Airline Division, GE Aerospace, Collins Aerospace, and the FAA present to answer questions about procedures and policies for aircraft maintenance.

The Accident

On November 4, 2025, a Boeing MD-11F operated by UPS crashed on takeoff from Louisville Muhammad Ali International Airport (KSDF) in Kentucky. The aircraft carried a full load of fuel as it was bound for Honolulu.

Video captured by CCTV shows flames around the No. 1 engine during the takeoff roll. The engine separated from the wing as the aircraft accelerated for takeoff from Runway 17R at 5:15 p.m. ET.

The jet lifted off briefly enough to clear the airport perimeter fence but could not continue the climb. The aircraft struck power lines and buildings, ultimately crashing about half a mile beyond the runway. A fire followed with flames shooting high into the air as thick black smoke obscured the scene.

The transcript of the cockpit voice recorder (CVR) indicates the crew knew they had an issue and fought to keep the aircraft in the air.

The crash killed all three crewmembers on board and 11 people on the ground. Another 23 people on the ground were injured.

According to the NTSB’s preliminary investigation, the MD-11 underwent a maintenance overhaul from September 3 to October 18. Those records have been scrutinized to determine if proper procedures were followed to verify the quality of the maintenance and the protocol for returning the aircraft to service.

Following the accident, authorities recovered the detached engine, a GE CF6-80C2, from the airport infield. The engine was found approximately 8,700 feet from the approach end of runway 17R, which measures 11,877 feet.

As a result of the accident, the MD-11 fleet in use around the world was temporarily grounded and underwent inspection, with a special focus on the engine attachment. Several operators reported finding cracks on the attachment pylons.

In January of this year UPS announced its decision to ground its MD-11 fleet. Other carriers are still using them.

‘Structural Defect’ Defined

The hearing began with the NTSB asking for the definitions of maintenance terms such as “structural defect” and what the process looks like when a maintenance technician finds a structural issue with an aircraft.

Much of the discussion focused on the spherical bearing, a part that allegedly failed, leading to a “migrating bearing” that weakened the engine pylon, resulting in its subsequent failure.

According to Tuesday’s testimony, as early as 2008 Boeing and UPS were aware the spherical bearings could fracture and migrate, but did not consider the design of the bearing a safety issue.

An NTSB animation of the part in use depicted how cracks could form and weaken the structure. A service letter issued by Boeing indicated that the spherical bearing should be inspected any time the rear bulkhead was inspected for migrating bearings. A service letter is not the same as an airworthiness directive (AD), as the latter is mandatory and requires the aircraft operator to act on it to keep the aircraft airworthy.

Boeing said it takes all safety concerns seriously and mitigates risks by increasing inspection intervals, changing maintenance procedures, and in some cases redesigning parts.

The hearing continues Wednesday.

In its preliminary report on the accident, the NTSB noted cracks were found in the left pylon, attributed to metal fatigue. The crash is still under investigation, and the agency’s final report is still several months away.

About the Airplane

The MD-11 involved in the crash had been flown by UPS since 2006. The aircraft type was originally manufactured by McDonnell Douglas, and later by Boeing, which acquired McDonnell Douglas in 1997.