FAA Proposes Fix to Thousands of 737s After Passenger Gets Stuck

After a passenger got stuck in the bathroom of a 737 for nearly an hour, the FAA has proposed a fix to nearly 3,000 planes that could cost Boeing and its customers up to $3.4 million. The flight that may have triggered this probe was forced to divert and free the passenger.

On April 11, the FAA published a notice of proposed rulemaking (NPRM) that would force operators to replace lavatory bifold door latches on certain Boeing 737-700, 737-800, 737-900, 737-900ER, 737 Max 8, and 737 Max 9 aircraft. While 3,461 of these jets have made their way to US customers, only around 2,612 would be included in the mandate.

Including parts and labor charges, the replacement could cost operators up to $481 per fix. With all factors together, if enacted, the airworthiness directive has a total price of up to $3.4 million. Fortunately, a warranty may cover some or all of the cost for airlines.

There are several reasons why a broken bathroom door latch could be problematic. Passengers and crew stuck inside could be at high risk during an “otherwise survivable emergency event”, prone to injury in poor weather, or become inaccessible during medical problems.

The FAA did not specifically tie an incident to its proposal. However, the agency did mention that flight attendants on a reported flight were unable to free a passenger from the restroom due to the aircraft’s bifold door latches failing. Mechanics met the plane on the ground after it diverted to assist.

An event in 2024 closely resembles the FAA’s statement. In 2024, a passenger on a SpiceJet 737-800 was trapped inside the bathroom for a flight from Mumbai to Bengaluru City. The crew’s attempts to open the door failed, and he remained in the bathroom for over an hour until landing.

Boeing and other stakeholders can respond to the proposal through May 27.

FMI: www.boeing.com