FedEx to return MD-11 freighters to service as FAA reviews fix after fatal crash
April 28, 2026
FedEx is preparing to return its MD-11 freighter fleet to service as early as next month, after a fatal crash forced regulators to ground the ageing cargo aircraft worldwide.
The move follows the successful development of a proposed engineering fix by Boeing, though the aircraft cannot resume operations until the US Federal Aviation Administration (FAA) approves the modification.
The global grounding was triggered by a deadly United Parcel Service (UPS) crash in November, which killed three crew members and 12 people on the ground. Now, while FedEx moves towards a cautious return, UPS has taken a different path, opting to retire the type entirely.
FedEx prepares to return MD-11 to service with Boeing fix
“They’re ready to go,” Richard W. Smith, FedEx’s chief executive of airline operations, said during a Wings Club event in New York, indicating the company is poised to bring the tri-jet freighters back once regulatory clearance is secured.
The development, first reported by Cargo Facts and The Wall Street Journal, marks a turning point for an aircraft type that has been at the centre of one of the most serious cargo aviation incidents in recent years.
FedEx has worked closely with Boeing to develop a technical fix centred on a redesigned bearing within the engine pylon structure, which investigators believe was a key failure point.
According to internal communications, Boeing has tested and produced a new component aimed at addressing the fatigue issue. FedEx says it has validated the solution and is now awaiting final FAA approval.
“The company is working in close consultation with Boeing, the FAA and the NTSB,” a FedEx spokesperson said, adding that operational teams and pilots have been kept informed as the return-to-service plan takes shape.
The airline is targeting a phased reintroduction, with a limited number of aircraft expected to return initially.
For FedEx, the stakes are significant. The company operates the world’s largest MD-11 freighter fleet, around 30 aircraft, making it a core part of its domestic and regional cargo network.
The grounding has come at a cost. FedEx has had to lease replacement aircraft and rework its network, taking a hit of more than $145 million in the months following the disruption.
Fatal crash and fatigue cracks behind global MD-11 grounding
The grounding of the global MD-11 fleet was triggered by a catastrophic accident in November, when a UPS freighter crashed shortly after take-off from Louisville’s Muhammad Ali International Airport.
Investigators found that the aircraft’s left engine detached during the take-off roll, with early evidence pointing to structural failure in the pylon assembly connecting the engine to the wing.
The accident killed three crew members and 12 people on the ground, prompting immediate regulatory action.
The FAA issued an emergency airworthiness directive mandating inspections across the global MD-11 fleet. FedEx, UPS and Western Global Airlines all grounded their aircraft “out of an abundance of caution”, bringing operations of the type to a near standstill.
Further investigation identified fatigue cracks in the pylon bearing assembly, along with evidence of overstress failure.
The issue was not entirely new. Boeing had previously alerted operators to potential cracking risks more than a decade ago, but replacement had not been mandated.
Investigators also noted similarities with the 1979 American Airlines Flight 191 crash involving a DC-10, an aircraft from which the MD-11 is derived, renewing scrutiny of ageing widebody freighters still in service.
UPS retires MD-11 fleet and accelerates shift to newer freighters
While FedEx is preparing to bring the aircraft back, UPS has opted to permanently retire its MD-11 jets. Before the crash, UPS operated 26 MD-11 freighters, representing around 9% of its fleet.
In its place, the company is accelerating investment in newer twin-engine aircraft, particularly the Boeing 767 freighter, with additional deliveries planned through 2027.
UPS executives said the grounding period demonstrated the flexibility of its network, with the airline able to reposition aircraft, increase ground transport capacity and lease additional lift to maintain operations.
The decision reflects a broader industry shift away from older tri-jet freighters towards more fuel-efficient and operationally flexible twin-engine aircraft.
When will FedEx MD-11s return to service?
For now, the return of the MD-11 hinges entirely on regulatory approval.
The FAA’s airworthiness directive grounding the aircraft remains in effect, pending validation of Boeing’s proposed fix and the issuance of a formal inspection and modification procedure.
Only once that process is complete can operators begin returning aircraft to service.
FedEx is expected to begin a phased reintroduction, supported by internal briefings for crews and operational teams, rather than an immediate full-scale return.
Despite its age, the MD-11 remains a valuable asset for FedEx, particularly for high-frequency domestic cargo routes where its payload capacity and performance still offer advantages.
The current episode highlights both the continued importance of the aircraft and the risks associated with ageing platforms, even as the industry gradually transitions to newer freighter types.
Featured image: zapper / stock.adobe.com
