LOUISVILLE, Ky. — The MD-11 cargo planes, the same model involved in a fatal UPS crash last fall at Louisville's Muhammad Ali International Airport, have returned to service after months of grounding and modifications. The Federal Aviation Administration announced over the weekend that it had approved Boeing's safety fixes for the aging aircraft, allowing FedEx to resume flights with its fleet starting Sunday.
The crash occurred on November 15, 2025, when a UPS MD-11 bound for Hawaii lost its left engine shortly after takeoff, causing the plane to veer off the runway and burst into flames. The incident killed all three pilots aboard — Captain Jason Hill, First Officer Mark Reynolds, and Flight Engineer Sarah Kline — as well as 12 people on the ground, including airport ground crew and bystanders near the runway. According to the National Transportation Safety Board (NTSB), the engine separation was linked to a failure in a critical spherical bearing that secures the engines to the wings.
In the immediate aftermath, the FAA grounded all MD-11s operated by U.S. cargo carriers due to safety concerns. The planes, originally designed and built by McDonnell Douglas in the 1990s before the company was acquired by Boeing, have been a staple in the freight industry despite their age. UPS, which lost the aircraft in the crash, decided earlier this year to retire its entire fleet of 53 MD-11s, representing about 9% of its total aircraft. The carrier cited the grounding and ongoing investigations as factors in the decision to phase out the model.
FedEx, however, took a different approach. The company, which operates 46 MD-11s accounting for roughly 4% of its fleet, committed to returning the planes to service after implementing Boeing's proposed remedies. Even prior to the crash, FedEx had been storing more than two dozen of its MD-11s due to operational efficiencies, but it pressed forward with inspections and repairs in collaboration with Boeing and FAA regulators.
"The Federal Aviation Administration said it approved Boeing’s proposed fix for the workhorse MD-11s ‘after extensive review,’" the FAA stated in a release. Boeing's solution involves replacing the problematic spherical bearing in the engine pylon assembly and increasing the frequency of inspections for similar components on all MD-11s. The manufacturer developed the plan following detailed analysis of the crash wreckage and historical data.
The NTSB's preliminary findings added context to the incident. Investigators noted that in 2011, Boeing had documented four previous failures of the spherical bearing on three different MD-11 aircraft. At the time, the company determined that these incidents "would not result in a safety of flight condition," according to NTSB documents. However, the Louisville crash prompted a reevaluation, leading to the current grounding and retrofit requirements.
FedEx emphasized its rigorous compliance with the new standards. In a statement, the company said it "worked closely with Boeing, the FAA and its own experts to inspect and repair its planes, and the government certified that it had complied with Boeing's recommendations." The carrier added, “Safety is our highest priority at FedEx.” Despite the resumption of flights, FedEx has long-term plans to retire the MD-11s in favor of more fuel-efficient models like the Boeing 777F, a strategy announced well before the UPS tragedy.
Not all operators of the MD-11 have been as forthcoming. Western Global Airlines, another cargo carrier that uses the aircraft, has remained silent since the crash. The company did not respond to inquiries about the FAA's decision or its plans for its fleet, which includes several MD-11s. Industry observers speculate that Western Global may follow UPS's lead in retiring the planes, though no official announcement has been made.
Aviation attorneys representing families affected by the Louisville crash expressed cautious optimism about the fixes but urged continued vigilance. Bradley Cosgrove, a lawyer handling lawsuits against Boeing and UPS on behalf of some victims' relatives, said, “We hope the FAA does a thorough job of investigating the fixes before the MD-11 fleet is allowed to return to flight.” The lawsuits allege negligence in maintenance and design oversight, seeking damages for the loss of life and property.
Experts in aviation safety offered mixed reactions to the timeline of the return to service. Jeff Guzzetti, a former crash investigator for both the NTSB and FAA, expressed confidence in the repairs. “I’m confident that the solution will work, and I would like to see the MD-11s back up in the air. It will be a safe airplane with regards to its engines after these corrective actions are made,” Guzzetti said. He noted surprise at the length of the grounding, given that the NTSB identified the bearing failure as a key factor relatively quickly.
Other analysts had speculated post-crash that the MD-11s might be grounded indefinitely if repair costs outweighed their value. These older planes, some over 30 years old, face increasing maintenance challenges in an industry shifting toward newer, more reliable aircraft. Boeing's relatively straightforward fix — focusing on the bearing replacement and enhanced inspections — appears to have alleviated those concerns, at least for now.
The MD-11's history in cargo operations provides important background. Introduced in 1990, the wide-body freighter was designed for long-haul routes, carrying heavy loads of packages, mail, and perishables. Its three-engine configuration offered reliability for transoceanic flights, but the model has faced scrutiny over the years for engine pylon issues and other structural concerns. The Louisville crash marked the first fatal hull loss of an MD-11 in U.S. cargo service, though the type has been involved in prior incidents worldwide.
As the planes take to the skies again, the NTSB is preparing to hold investigative hearings next week in Washington, D.C. The two-day sessions will feature testimony from Boeing engineers, FAA officials, and UPS maintenance crews, delving deeper into the crash's causes and potential preventive measures. Investigators aim to finalize their report within the next year, which could lead to additional regulatory changes for legacy aircraft.
The return of the MD-11s underscores broader tensions in the aviation freight sector. Cargo demand has surged with e-commerce growth, pressuring carriers to maximize fleet utilization. Yet safety regulators and operators must balance operational needs with rigorous oversight, especially for aging fleets. FedEx's decision to fly again contrasts with UPS's retirement, highlighting differing corporate strategies in the wake of tragedy.
While the fixes address the immediate engine attachment risks, questions linger about long-term viability. Aviation lawyer Cosgrove and others worry that stepped-up inspections could strain resources without eliminating all hazards. Guzzetti, however, believes the modifications will restore confidence, allowing the MD-11 to serve reliably until full retirement. For the families still grieving the Louisville losses, the planes' return evokes a mix of relief and apprehension, as legal battles and investigations continue.
In the end, the saga of the MD-11 reflects the evolving landscape of air cargo, where innovation clashes with the realities of maintaining decades-old technology. As FedEx packages soar overhead once more, the industry watches closely for any signs of trouble, determined to prevent another runway disaster.
Sarah Mitchell reports for The Appleton Times from Louisville, Kentucky. Associated Press writer Jack Dura contributed to this report from Bismarck, North Dakota.