FAA Proposes New Crack Inspections for Challenger 604 Wings and Tail
Why It MattersFleet-wide structural inspections on a mature large-cabin type add recurring downtime and maintenance planning demands for Challenger 604 operators and the shops that service them.
The FAA has proposed a new airworthiness directive for certain Bombardier CL-600-2B16 (Challenger 604) aircraft, following reports of cracks on the lower wing plank at the rear spar.
Under the proposal, operators would inspect the lower wing plank rear spar web and lower flange, the forward surface of the pressure bulkhead frame under the stiffeners, and the lower legs of the vertical stabilizer front spar-to-frame attachment fitting. Any cracking found would require corrective action. Maintenance providers would need to incorporate the inspections into scheduled visits and document compliance in the aircraft's maintenance history.
The FAA estimates the inspections would take up to 24 labor hours per aircraft at $85 per hour, for a cost of up to $2,040 per aircraft. The agency counts 201 affected aircraft on the U.S. registry and says it does not have definitive data to estimate repair costs where cracking is found. If adopted, operators would need to build the inspections into future maintenance planning and account for aircraft downtime, which can run to days depending on shop scheduling and workload.
