MD-11 Cargo Fleet Returns to Service After FAA Approval

The McDonnell Douglas MD-11 cargo aircraft fleet, grounded after a catastrophic failure last year, has begun returning to service. FedEx resumed operations with the type over the weekend following the Federal Aviation Administration (FAA) approval of a Boeing-developed technical solution.

The decision lifts a fleet-wide grounding that was implemented after a UPS MD-11 crashed in November 2025 in Louisville, Kentucky. The incident, which resulted in the deaths of three flight crew members and 12 individuals on the ground, occurred when the aircraft's left engine detached from the wing during takeoff. The return to service for a portion of the global fleet marks a significant milestone in addressing the safety concerns raised by the crash.

Background of the Grounding

The grounding order from the FAA affected all operators of the MD-11 freighter. The catalyst was the November 2025 crash of a UPS MD-11 departing Louisville Muhammad Ali International Airport (SDF) for Hawaii. Investigators from the National Transportation Safety Board (NTSB) quickly focused on the structural failure of the engine pylon, which connects the engine to the wing.

In response to the accident, UPS made the decision to permanently retire its entire MD-11 fleet earlier this year. The aircraft comprised approximately 9% of the company's total fleet. In contrast, FedEx, which operates 46 of the aircraft, representing about 4% of its fleet, remained committed to working with regulators and the manufacturer to return the aircraft to service.

A third U.S.-based operator, Western Global Airlines, has not made any public statements regarding the status of its MD-11 fleet since the grounding.

The Approved Technical Solution

Following an extensive review, the FAA approved a corrective action plan developed by Boeing, which acquired McDonnell Douglas in 1997. The solution centers on the replacement of a critical spherical bearing within the engine pylon assembly. In addition to the part replacement, the approved plan mandates an enhanced inspection protocol for the components that secure the engines to the wings across the remaining active fleet.

Scrutiny of the component's service history revealed prior issues. The NTSB noted that as early as 2011, Boeing had documented four previous failures of the same part on three different MD-11 aircraft. At that time, the manufacturer had reportedly determined that such a failure would not result in a critical safety-of-flight condition. The NTSB is scheduled to hold two days of investigative hearings on the UPS crash next week to further examine the accident's causal factors.

Operator and Industry Response

FedEx confirmed its compliance with the FAA's directive and Boeing's recommendations. In a statement, the cargo carrier said it worked closely with Boeing, the FAA, and its own internal experts to inspect and repair its aircraft. "Safety is our highest priority at FedEx," the company stated.

Despite the return to service, the long-term future of the MD-11 at FedEx is limited. The company had announced plans to eventually retire the aging tri-jet freighters in favor of more modern and efficient twin-engine models even before the 2025 accident.

Aviation safety expert Jeff Guzzetti, a former investigator for both the NTSB and FAA, expressed confidence in the approved fix. “I’m confident that the solution will work, and I would like to see the MD-11s back up in the air," Guzzetti said. "It will be a safe airplane with regards to its engines after these corrective actions are made.”

However, legal representatives for the families of crash victims have expressed caution. “We hope the FAA does a thorough job of investigating the fixes before the MD-11 fleet is allowed to return to flight,” said lawyer Bradley Cosgrove.

Why This Matters

The return of the MD-11, a key workhorse in global air cargo, demonstrates a regulatory pathway for addressing critical in-service safety issues on aging aircraft. The event also highlights the differing fleet strategies between major operators like FedEx and UPS when faced with significant airworthiness directives and the associated costs of compliance versus accelerated retirement.