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From Kathleen Koch (CNN)
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WASHINGTON (CNN) -- Four new cases of possibly faulty fuel pumps that could lead to explosions have prompted Boeing to advise airlines to examine the pumps on every single Next-Generation 737, as well as all 747s and 757s.
"We're not going to take the risk," said Boeing spokesperson Liz Verdier. "We want to maintain the continuing safety of the fleet."
The service bulletin went out to airlines Friday, recommending they conduct an X-ray screening of the fuel pumps in the center fuel tank.
The order affects more than 1,400 aircraft in the United States, and 3,200 worldwide.
On August 30, the Federal Aviation Administration issued an emergency order for airlines to check to see if their planes had a newly redesigned fuel pump in which chaffed or misaligned wires could cause sparking and possible explosion in the center fuel tank.
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Upon examination, it turned out some 118 aircraft were affected.
The new service bulletin from Boeing comes after the pump maker -- Hydro-Aire -- went through its maintenance records for the past five years and discovered four more cases in which fuel pump wiring may have been an issue.
"None were improperly routed or had wire chafing," said Hydro-Aire President Greg Ward, although a press release from Hydro-Aire's parent company, Crane Co., said the pumps had "potentially similar chafing conditions" to those discovered in August.
When his company alerted Boeing and the FAA to the possible incidents, Ward said, the decision was made to have all fuel pumps of that model checked.
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While the first order involved 1,250 suspect pumps, the new one covers more than 30,000.
Until airlines can check their planes, Boeing advised them to keep enough fuel in the center wing tank to keep the pumps submerged -- even when banking, climbing or experiencing turbulence.
The new inspections will be more time-consuming than the checks last month since more planes are involved, Verdier said. "This is a burden to the operators," she said.
The fuel pumps will have to be removed from the planes in order to be X-rayed. Hydro-Aire has offered to cover the cost, an estimated $4 million.
Sources say the FAA is expected to issue an airworthiness directive to airlines next week with more details.
The SFAR
mandating fuel tank inerting
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