Boeing Redesigns 777X Thrust Links that Caused 4-Month Delay

WASHINGTON- Boeing has implemented a redesign of the engine thrust links for its long-awaited 777X widebody aircraft, addressing fatigue issues that previously resulted in a four-month delay in certification testing.

Aviation Week has reported that the American manufacturer intends to install the newly redesigned components later this summer as part of wider design enhancements.

Boeing’s original timeline anticipated the 777X certification for 2020, aiming to position the aircraft as a next-generation model in the well-regarded 777 widebody series.

This aircraft family has been engineered to provide advancements in efficiency, range, and passenger comfort when compared to existing widebody models.

The certification phase has included extensive flight testing utilizing four dedicated test aircraft specifically configured to validate the performance and safety of the new design.

Nevertheless, the certification timeline faced immediate hurdles due to technical issues that emerged during testing. In 2020, Boeing experienced a significant setback when an “uncommanded pitch event” caused the aircraft’s nose to lift unexpectedly, without any pilot command.

This situation led to prolonged certification delays as engineers worked diligently to rectify the flight control system anomaly and implement necessary safety enhancements.

August 2024 Thrust Link Failures

A recent major slowdown occurred in August 2024 when Boeing identified broken thrust links on one of the test aircraft during routine inspections.

Subsequent investigations uncovered similar cracks in the load-bearing components on other aircraft in the testing fleet. These thrust link failures resulted in Boeing temporarily grounding all four 777X test aircraft, completely halting the certification process.

The thrust links transfer loads between the engine and wing structure, with initial components exhibiting cracks that led to grounding all four test aircraft in the 777X program. Boeing resumed certification flights in mid-January 2025 after an interruption in operations that began in August 2024 due to the broken thrust links.

Following evaluations, Boeing engineers determined that fatigue issues in the original thrust link design were responsible for the failures, necessitating a comprehensive redesign of these crucial load-bearing elements. The grounding lasted four months while Boeing developed and tested the enhanced thrust link design.

Design Improvements

The manufacturer resumed certification flights in mid-January 2025 after implementing temporary solutions and conducting extensive ground tests of the new thrust link design. Aviation Week confirmed that Boeing now aims to install the final redesigned thrust links by summer 2025 as part of a comprehensive series of design enhancements.

Boeing aspires to complete 777X certification by late 2025 or early 2026, with first deliveries projected for 2026. This certification process requires approval from both the FAA and the EASA before the commencement of commercial operations.

Lufthansa (LH) is anticipated to be the first airline globally to receive the 777X once the certification process is successfully completed, according to Boeing CEO Kelly Ortberg.

Emirates (EK) is expecting to receive its Boeing 777X aircraft by the conclusion of 2026, despite earlier uncertainties regarding this timeline.

Emirates’ Chairman and CEO Sheikh Ahmed bin Saeed Al Maktoum reaffirmed this expectation during a media engagement at the Arabian Travel Market in Dubai. The airline is presently anticipating 205 Boeing 777X deliveries, making it the largest global customer for this aircraft model.

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