Boeing knew about critical engine part failures in 2011 but refused to mandate fixes, leading to the deadliest UPS crash in history when Flight 2976’s engine detached during takeoff, killing 15 Americans.

Boeing’s Fatal Oversight Exposed in NTSB Report

NTSB investigators revealed Boeing documented four identical spherical bearing race failures on MD-11 aircraft in 2011, affecting three different planes. Despite knowing this critical engine-mounting component was prone to cracking and fracturing, Boeing issued only an advisory bulletin rather than mandating immediate inspections or repairs. The company classified these failures as a “non-safety-of-flight issue,” a designation that aviation experts now question, given the catastrophic results in Louisville.

The November 4, 2025 crash occurred when the left engine of UPS Flight 2976 detached during takeoff from Louisville Muhammad Ali International Airport. The 34-year-old MD-11F cargo plane, carrying 20,000 packages and 38,000 gallons of fuel, reached approximately 200 mph before plowing into an industrial area. The spherical bearing race had cracked in multiple locations, causing the engine pylon to fail and separate from the wing.

Aging Aircraft Fleet Raises Safety Concerns

The crashed aircraft, N259UP, had not undergone a detailed engine mount inspection since October 2021 and wasn’t scheduled for another examination for roughly 7,000 flight cycles. Aviation experts argue that UPS’s fleet of 30-plus-year-old MD-11 freighters has exceeded its operational shelf life. Attorney Brad Cosgrove, representing crash victims, stated these aircraft should have been retired years ago, emphasizing that warning signs of potential catastrophic failure had been ignored by both Boeing and UPS.

UPS operates one of the world’s largest MD-11 cargo fleets from its Louisville Worldport hub, the planet’s busiest cargo airport. The McDonnell Douglas-built aircraft entered UPS service in the 1990s and has since logged many years of operation. Industry analysts question whether aging freighter aircraft receive adequate oversight compared to passenger jets, particularly regarding known mechanical deficiencies that manufacturers have previously documented.

Victims Pay the Ultimate Price for Corporate Negligence

The crash claimed 15 lives, including workers and customers at the Grade A Auto Parts yard where the burning aircraft struck. Witnesses reported serial explosions as fuel and cargo packages ignited, creating a massive fireball that required over 100 firefighters to contain. The initial death toll of 12 ground fatalities rose to 15 when another victim succumbed to injuries on Christmas Day 2025, making this the deadliest UPS crash in company history.

Lawsuits filed against Boeing and UPS cite the 2011 bulletin as evidence that both companies knew about the deadly risks but failed to take adequate preventive measures. The legal action highlights a disturbing pattern where corporate profits appear to have taken precedence over public safety, leaving innocent Americans to pay the ultimate price for regulatory failures and manufacturing shortcuts that prioritize cost-cutting over human lives.

Sources:

UPS Airlines Flight 2976 – Wikipedia

UPS cargo plane crash in Louisville caused by part that broke, failed: NTSB – CBS News

NTSB Investigation Report – UPS Airlines Flight 2976