The US Federal Aviation Administration (FAA) has issued a safety information bulletin recommending a series of checks for Boeing 757-200 converted freighters, following a 2021 incident in which a DHL Air aircraft’s main cargo door opened during flight.
Although the FAA has not issued an airworthiness directive, it is urging operators to conduct regular inspections and tests to prevent similar occurrences.
The Leipzig incident involved a Precision Conversions-modified aircraft, where the hydraulically operated main cargo door opened unexpectedly during climb.
The flight crew detected a sudden cabin pressure issue but received no instrument warning that the door had malfunctioned.
Precision Conversions’ modification includes mechanical latches and locking hooks, along with proximity sensors designed to ensure the door is secure.
The FAA recommends that operators perform “door-open,” “door-closed,” and “latched and locked” test procedures every 5,000 flight cycles as outlined in Precision Conversions’ manuals.
Additionally, operators should inspect view-port mirrors and windows for debris, check latches and lock pins for paint defects, and follow cold-weather operating procedures to prevent ice accumulation around the door mechanisms.
This is not the first reported issue with a converted 757 freighter. Russia’s federal air transport agency, Rosaviatsia, documented a similar event in December 2014 involving a Yakutia Airlines aircraft.
The jet took off from Magadan in extreme cold conditions, and its cargo door lifted fully open mid-flight due to compacted ice and snow in the locking mechanisms.
With these new recommendations, the FAA aims to enhance safety for operators of converted Boeing 757 freighters, ensuring door integrity in all flight conditions.