UPS plane that crashed in Kentucky had a component that previously failed four times on other aircraft.

In a crucial update regarding the tragic crash of a UPS aircraft in November 2025, the National Transportation Safety Board (NTSB) has revealed that Boeing had previously informed plane owners about a potentially dangerous component but did not classify it as a safety threat at the time. This warning dates back to 2011 and pertains to a part critical for securing the engines of the MD-11, previously manufactured by McDonnell Douglas, which was acquired by Boeing.

The incident occurred shortly after the aircraft took off from Louisville, Kentucky, resulting in the loss of three pilots and 12 individuals on the ground. During the flight’s initial ascent, the left engine detached from the wing, leading to the catastrophic crash.

The NTSB’s investigation disclosed that Boeing had documented four earlier failures of this specific component in three separate aircraft. Nonetheless, the company concluded that these issues did not warrant a declaration of a safety risk. The investigative body expressed concern over the apparent lack of thorough maintenance checks, with the last comprehensive inspection of the engine mount parts having been conducted in October 2021. At the time of the accident, approximately 7,000 takeoffs and landings were expected before another such detailed examination would occur.

This recent disaster draws parallels to a notable aircraft failure from 1979, where an American Airlines DC-10 lost its left engine during takeoff, resulting in 273 fatalities. Although extensive scrutiny followed that incident, which led to a grounding of similar aircraft, it was ultimately found that improper maintenance, rather than design failures, contributed to the crash.

Experts in aviation safety have voiced their concerns regarding the adequacy of Boeing’s 2011 service bulletin, which recommended replacing the spherical bearing but allowed for the continued use of older, defective parts. Some argue this lax approach may have played a role in the Louisville tragedy, highlighting the need for stricter maintenance protocols for aging aircraft.

Following the crash, the NTSB identified broken components linked to the engine’s detachment, but a definitive cause has yet to be established. The final report from the NTSB is expected to arrive more than a year after the event, with ongoing investigations focusing on Boeing’s prior communications and the subsequent actions taken by UPS in response to the 2011 alert.

In the interim, the 34-year-old aircraft involved in the accident has generated significant concern due to its age and the cessation of commercial flights of such planes, largely because they are outclassed by more efficient modern models. Both Boeing and UPS have refrained from making public statements pending the investigation’s conclusion, although they have expressed condolences to the victims’ families.

The investigation’s findings are anticipated to have substantial implications, especially as lawsuits related to the crash emerge, which will scrutinize both Boeing’s prior knowledge and UPS’s adherence to maintenance advisories. The implications of these events urge discussions about the operational viability and safety standards of legacy aircraft.