Western Global Airlines has returned one of its MD-11F freighters to active service, the carrier confirmed in late May, adding capacity amid sustained demand for air cargo lift. The aircraft, registration N781SN, returned to service on May 23 and is the first from the carrier’s grounded fleet to resume operations since the Federal Aviation Administration approved a corrective action developed by Boeing.
The FAA’s clearance followed a Boeing-engineered remedy for a problem with the pylon attachment that secures the tri-jet’s rear engine. The issue came under scrutiny after a fatal UPS MD-11 crash in 2025, which the NTSB linked to pylon failures. Investigators later questioned why earlier bearing defects on multiple MD-11s did not prevent the accident.
FedEx, the largest MD-11 operator, was the first operator to return its aircraft to service after received FAA approval. The express carrier performed a test flight in May to test Boeing modifications able to restore operations after the fleet-wide grounding imposed after the UPS accident.
UPS itself retired its entire MD-11F fleet following the FAA suspension. The carrier accelerated the withdrawal of the aging freighters and recorded a write-off as part of its fourth-quarter 2025 results, choosing not to pursue the repairs required for return to service.
Western Global’s reactivation provides additional lift in a market where air cargo demand remains firm. With 15 aircraft, the carrier operates a smaller MD-11 fleet compared with FedEx and UPS, but the return of even one aircraft adds flexibility for charter and scheduled services.
The Boeing fix addresses structural concerns with the pylon attachment points, an area that the NTSB flagged as a recurring safety issue. The FAA approved the modification after reviewing engineering data and testing results submitted by Boeing.
Other MD-11 operators have also begun the process of returning aircraft to service, though timelines vary depending on maintenance schedules and regulatory approvals. Western Global did not disclose how many of its remaining MD-11s it plans to reactivate.
