FAA Safety Bulletin: Boeing 757 Cargo Door Safety

‍DALLAS — The Federal Aviation Administration (FAA) has issued a Special Airworthiness Information Bulletin (SAIB 2025-02) addressing potential safety concerns regarding the main deck cargo door on certain Boeing 757-200 series aircraft converted from passenger to freighter configuration (PCF).

The bulletin, released on February 21, 2025, follows an incident in 2021 where a Boeing 757-236 freighter experienced an in-flight opening of its main cargo door during its initial climb. 

While the flight crew returned safely to their departure airport with no injuries reported, the incident highlighted potential risks with the cargo door system.

The affected aircraft—modified under Precision Conversions LLC's Supplemental Type Certificate (STC) No. ST01529SE—are equipped with hydraulically operated main deck cargo doors that use mechanical latches, locking hooks, and proximity sensors to monitor the door's position.

SAIB Recommendations

The FAA's recommendations include several maintenance procedures to be performed every 5,000 flight cycles or hours, depending on the specific test:

• Door open and closed testing
• Verification of door-locking mechanisms
• Inspection of viewing ports and locking components
• Regular cleaning and maintenance of door components

Additionally, the bulletin emphasizes the importance of proper cold weather operations, including removing ice and snow accumulation around the cargo door mechanisms and conducting additional inspections after exposure to freezing conditions.

Difference Between SAIB and AD

A Special Airworthiness Information Bulletin (SAIB) provides recommendations and alerts operators to potential safety issues, but compliance is voluntary. In contrast, an Airworthiness Directive (AD) is a legally enforceable regulation that requires operators to correct an unsafe condition within a specified timeframe. 

The FAA issues SAIBs when it identifies potential safety concerns that don't yet rise to the level of requiring an AD. However, the agency continues its investigation and, depending on its findings, may consider future regulatory action.

Operators experiencing cargo door malfunctions are encouraged to report them to the FAA, with reports to be submitted under OMB Control Number 2120-0731. Operators can contact the FAA's Aviation Safety Engineer Tony Koung or Precision Conversions LLC's support team for technical assistance.

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