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Boeing and Spirit AeroSystems have completed a redesign of the door plugs on the Boeing 737 MAX 9, as reported by Flight Global. The redesign aims to prevent incidents like the one involving Alaska Airlines flight AS1282, where a door plug blew out mid-flight in January 2024. This incident raised concerns about Boeing's manufacturing processes.
The blowout was attributed to improper reinstallation of a plug by Boeing employees at their Renton facility. Workers failed to install four critical bolts, leading to explosive decompression. Fortunately, no serious injuries occurred during this incident.
Boeing has introduced six new features in the redesigned door plugs. These include two retention arm assemblies that prevent misalignment with the fuselage and ensure proper installation. Additionally, four safety wire "lanyards" are now permanently attached to provide visual confirmation of correct installation without hindering removal or installation.
