FedEx is preparing to return its grounded MD-11 cargo aircraft to service by the end of May, despite regulators not yet lifting the flight ban imposed after a deadly crash last year.
The company plans to reactivate 28 MD-11 freighters with support from Boeing, installing a newly designed bearing to fix a structural issue in the engine pylon—the component that attaches the engine to the wing.
According to an internal bulletin shared with employees, the new part addresses a design flaw linked to the grounding of the aircraft.
In a separate memo, FedEx told pilots it intends to begin operating two MD-11 aircraft in May. Pilots will be required to complete a three-day refresher course to ensure they are fully prepared to return to flying the aircraft.
The Federal Aviation Administration grounded all MD-11 aircraft after the crash of UPS Flight 2976 in Louisville, Kentucky, in November, when an engine detached from the wing during takeoff. Investigators later identified fatigue cracks in the structure connecting the engine to the wing.
FedEx said it has worked closely with Boeing to complete engineering analysis and develop maintenance procedures, including designing, testing, and producing the new bearing.
“With the production of the new bearing, our engineering, aircraft maintenance, and quality control teams were able to successfully validate Boeing’s proposed maintenance actions,” the company said in the bulletin.
However, the FAA must still approve the repair procedures before FedEx can resume MD-11 operations.
The company has scheduled a town hall meeting for pilots and staff on May 6 to discuss Boeing’s findings, repair plans, safety measures, and the timeline for returning the aircraft to service. The meeting will take place at a FedEx training facility near its Memphis hub and will also be streamed online.
The National Transportation Safety Board continues to investigate the crash, and regulators have not yet indicated when inspections will be completed or when the aircraft may be cleared to fly again. Boeing declined to comment.
FedEx has remained optimistic about returning the MD-11 fleet to service, while UPS has decided to retire its MD-11 aircraft entirely. Another operator, Western Global Airlines, has not announced its plans.
The company previously estimated the aircraft could return between March and late May. During the grounding, FedEx spent about $175 million to offset lost capacity by using other airlines and operational adjustments.
Executives have expressed confidence that the MD-11 will safely return to service, noting that continued use of the aircraft helps meet growing demand for cargo transport and reduces reliance on leased aircraft.
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