Boeing to rework 30 stored 777X jets before 2027 delivery
Boeing's CEO says 30 completed 777X aircraft require extensive modifications due to design changes from flight testing, with a dedicated team working to
Boeing CEO Kelly Ortberg disclosed that approximately 30 already-built 777X aircraft will need significant rework before they can be delivered to airlines. The modifications are required to update early-production planes with design changes identified during the prolonged flight-testing and certification program, with first deliveries of the 777-9 variant still targeted for 2027.
The aircraft were built years ago while the 777X design was still evolving. Ortberg described the required "change incorporation" process as a "pretty massive activity." The oldest airframes in storage will require the most extensive structural changes, while newer builds will need only minor software and systems updates.
A costly build-and-store strategy
Boeing continued producing 777X jets to support the certification process and keep its widebody assembly line active. Shutting down and restarting such a production line is extremely expensive and could cause major workforce and supply-chain disruptions. However, this strategy has locked up a substantial capital investment. The 30 completed aircraft occupy storage space at Seattle Paine Field International Airport and cannot generate revenue until modified.
The scale of the modifications
The scope of work varies significantly by the airframe's age. CEO Kelly Ortberg stated that older aircraft would require "more structural-related changes." Industry analysts believe the rework could involve opening completed fuselage and wing sections, replacing structural components, and updating avionics. The goal is to bring all stored aircraft to a common configuration before applying final certification updates, a process expected to take several years.
A dedicated team for a complex task
Boeing has established a dedicated team to manage this extensive rework program. This move highlights the scale of the challenge, especially given recent workforce pressures. In late 2024, Boeing announced plans to cut about 10% of its global workforce, affecting hundreds of engineers. The company has also struggled with the complexity of certifying the 777X's new composite wing and a revised fuselage manufacturing process.
Certification milestones and next steps
Despite the delays, the certification program is advancing. In March 2026, the FAA authorized Boeing to begin Phase 4A of the Type Inspection Authorization (TIA) process for the 777-9. This phase focuses on natural icing tests, currently believed to be taking place in Alaska. Boeing is awaiting approval to begin Phase 4B testing. The remaining certification phases and subsequent ETOPS evaluations must be completed before the 2027 delivery target.
The manufacturer stated in its first-quarter 2026 results that the 777-9 program "continued to make progress" on certification. Assuming no major setbacks, Boeing believes it has sufficient time to complete the required testing and modifications for its launch customers, which include Emirates and Lufthansa.
