United’s Fancy New Boeing 787 Has Some Serious Maintenance Issues…

United’s Fancy New Boeing 787 Has Some Serious Maintenance Issues…

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United Airlines recently began service with its newest Boeing 787-9. While the airline already has a huge Dreamliner fleet, this plane is special, given that it has the carrier’s all-new interiors, and it’s in a very premium configuration. This is a plane that many United frequent flyers have been excited to fly, but actually doing so has proven to be challenging (thanks to Kevin for flagging this)…

United’s new Dreamliner was grounded twice in days

N61101 is the registration code for United’s first new Boeing 787-9, which also has the United 100th anniversary decal on it, and it’s the first plane with new interiors. The plane’s first international route is between San Francisco (SFO) and Singapore (SIN), with service commencing on April 22, 2026.

So, how has that worked out so far? The inaugural long haul flight from San Francisco to Singapore, with flight number UA1, operated as planned, landing in Singapore on the morning of April 24, after a 16hr31min journey. The plane was then supposed to turn around and operate as flight number UA2 back to San Francisco.

The plane took off from Singapore, only for the crew to make the decision to return to Singapore due to an electrical smell onboard. It landed in Singapore safely after a roughly 1hr50min flight. Stuff happens, so while the timing is unfortunate, you wouldn’t think much of it.

The new Boeing 787’s second long haul flight diverted

A day later, on April 25, the plane was then ferried (without passengers) back to San Francisco, with flight number UA3968, and that flight took 15hr5min. There the plane was grounded for three days, so that the plane could undergo maintenance.

On April 28, the plane performed a test flight around San Francisco, with flight number UA4196, which lasted 48min. Presumably the maintenance folks signed off on the plane, so it could reenter service, initially once again flying domestically. How have things gone since then?

  • On April 28, the plane flew to Houston (IAH) with flight number UA2047, in a flight time of 2hr55min
  • On April 29, the plane flew back to San Francisco with flight number UA487, in a flight time of 3hr51min
  • On April 29, the plane flew back to Houston with flight number UA2498, in a flight time of 3hr11min
  • On April 29, the plane was supposed to fly back to San Francisco with flight number UA382, but that flight ended up being canceled due to maintenance issues
The new United Boeing 787 had a second maintenance issue

To state the obvious, having two cancelations in a matter of days on a brand new plane is less than ideal. It’s not publicly known if the two maintenance issues might be related.

How can you explain United’s issues with its new Boeing 787?

I’m not really a conspiracy theorist, and I also don’t have any insights or expertise into the minutiae of Boeing 787 maintenance to have an educated guess here. My default assumption would be that this is just really bad luck in terms of timing, and that there’s probably not more to this. That being said, two thoughts come to mind.

First, with the plane having new cabins (and presumably different wiring associated with the seating), I imagine it can’t totally be ruled out that the interiors may have in some way contributed to electrical issues? I mean, the seats are certified, and similar seats are available on other airlines, so you wouldn’t assume there’s an issue, but…

The plane with issues has United’s newest interiors

Second, here’s what I also find interesting. Remember last year, when American inducted its brand new Boeing 787-9s, with all-new interiors? Well, one of those Dreamliners had an absolutely brutal maintenance record for the first several weeks in which it was in service. Reports at the time suggested that the issues there involved engines and/or door alignment, so that seems to have less possibility of being related to interiors.

Anyway, it’ll be interesting to keep tracking this new United Dreamliner, as hopefully its reliability improves soon.

American’s new Boeing 787 also initially had maintenance issues

Bottom line

United Airlines’ “milestone” Boeing 787-9 with new interiors is having some serious issues. The return sector of the inaugural international flight had to divert back to Singapore, due to an electrical smell onboard. The plane was ferried back to the United States and out of service for three days, so that it could undergo maintenance. Then within a day of reentering service, there was once again a maintenance issue, leading to a flight being canceled. That’s some bad luck, or something!

What do you make of United’s issues with its new Dreamliner?

Conversations (32)
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  1. AJ Denver Guest

    Boeing fanboy here. Likely because we build planes so strong they don’t need aligned doors or doors at all (see Alaska blowout and safe landing). Probably forgetting doors and such because they are buried in new orders. Push em out, even broken they aren’t French with german electrical. I can hear weird grinding and screeching as we lift off now.

  2. Anthony Guest

    Built in America, built by Boeing. When is America going to be the best manufacturer? Or not.
    Maybe America sits by and watches China zoom past. Airplane manufacturing is up and coming in China, just like everything else, from blood thinners for American hospitals to exact scientific instruments.

  3. Tim Dunn Diamond

    and to think this aircraft was delayed being delivered to United by a matter of years... even as UA has scores of airplanes - not just Boeings - grounded due to engine problems which is not at all Boeing's fault because Boeing doesn't build engines

  4. AeroB13a Guest

    The silence of the Boeing fanboys is deafening!
    Perhaps they are sick to their back teeth of attempting to defend the indefensible?

    1. Eskimo Guest

      Like the silence of de Havilland.
      Too busy killing people.

    2. TJ Guest

      Why silent..
      It happens , nothing new..
      Instead of getting on Boeing ,how about looking back a few years about a new A350 delivered to British Airways with a host of issues as soon as it entered service .
      Another memorable Lemon..

  5. JamesBond Guest

    You're putting it all on the new interior. How about the manufacture of the airplane. I foresee more electrical gremlins from another yet to be certified airplane model from the same manufacture.

  6. TM Guest

    It's reportedly a door issue. This same aircraft was taken out of service in early April while on its domestic circuit. MX flew two test flights on 4/11 and 4/15 and then returned it to service on 4/19. It operated a few more domestic segments prior to entering international service on 4/22.

  7. betterbub Diamond

    For Tim Dunn this is the equivalent of winning the Super Bowl

    1. Eskimo Guest

      Nah, Tim has no clue about a big bowl filled with chips.

      He thinks the Seahawks suck because SEA is a Delta fortress and adding a 12th person will be a cost disadvantage against Delta.

      He thinks NY Jets sucks because every Jets in NY are slot restricted
      He also knows NY Giants is actually in NJ and EWR sucks too, just ask UA.

      Meanwhile Tim enjoys who dat French lily flower sticking up his behind because it adds to his bottom line.

    2. Kris Guest

      IIRC Delta spent like $100M to become "the official airline of the seattle seahawks" it was like 5x more than Alaska had paid before. Maybe they should look to cut costs there rather than laying off staff at corporate HQ

  8. M. Casey Guest

    According to the UA fleet site at Google Docs - there is a 787-8 that has been grounded for over 2 months in ORD. Last flight was 2/08 OGGORD.

    https://docs.google.com/spreadsheets/d/1ZlYgN_IZmd6CSx_nXnuP0L0PiodapDRx3RmNkIpxXAo/htmlview#gid=13

  9. luke Guest

    maybe united should have been smarter and test run the plane on domestic routes first.

    Kirby your competitor thought of that!

    1. Mike Guest

      lol they did for a month SFO IAH

  10. 1990 Guest

    And, maintenance issues... are under the control of the airline... not an 'extraordinary circumstance.' So... we really should have air passenger rights, including compensation, when excessive delays and cancellations are under airlines control (see EU261, Canada's APPR.) So, these passengers are mostly screwed (maybe the airline helps with rebooking, accommodations, but other than a (often 'partial') refund, they don't technically have to do anything under US law). Hopefully the US will catch-up someday soon. We...

    And, maintenance issues... are under the control of the airline... not an 'extraordinary circumstance.' So... we really should have air passenger rights, including compensation, when excessive delays and cancellations are under airlines control (see EU261, Canada's APPR.) So, these passengers are mostly screwed (maybe the airline helps with rebooking, accommodations, but other than a (often 'partial') refund, they don't technically have to do anything under US law). Hopefully the US will catch-up someday soon. We deserve better.

    1. Walter Guest

      Luckily the European airlines can recoup there money with issues relating to EES and stranding plus passengers at the airport

    2. Eskimo Guest

      So you want EU261 like.
      Unionized employee.
      But refuse government bailout.

      Flying will not be affordable for everyone anymore.

    3. rrapynot Guest

      Are you familiar with Ryanair, Wizzair and EasyJet? They have to abide by EU261 but have very cheap fares and they are profitable.

      Have you heard of British Airways, Air Grande and Aer Lingus? They are all union airlines an have to abide by EU261 but have very cheap fares inside Europe an are all profitable.

      Passenger rights and unionised employees don’t equal unprofitability. Poor management does though.

  11. George Guest

    My question is: does anyone knows if something similar happens with the A350 family? Or the A330neo?
    If not, this in fact prove that something is quite off at Boeing

    1. Justin Guest

      Towards the end of 2024, Malaysia Airlines called Airbus out for hydraulic issues on a brand new A330NEO, and called Rolls Royce out for engine issues on that same brand new A330NEO

    2. Justin Guest

      There are also videos on social a passenger filmed by where an American Airlines A321XLR captain was on the PA saying that the aircraft was having computer issues. Mind you, AA’s XLRs entered service only a couple of months ago.

    3. Vf2007 Guest

      I've been delayed/cancelled way too often with Deltas A330neos. I try to avoid them if possible.

  12. AeroB13a Diamond

    Is it too soon to repeat that popular saying …. “If it’s a Boeing, I ain’t going?

    …. and some ORDinary people have the audacity to berate Airbus products …. :-)

    1. 1990 Guest

      At least, if these flights originated in the UK or EU, these passengers would likely be eligible for hundreds of dollars/pounds/euros in compensation in addition to rebooking or refund, thanks to UK/EU261. However, since US has no such rules, these affected passengers can 'pound sand' or 'kick rocks,' as they say.

    2. ORD_Is_My_Second_Home Diamond

      Yes, I do. A lot of us Americans bake in the Built On Friday trope to complex machinery. The only advantage stinky Airbii has is access to German engineering.

  13. BenjaminKohl Diamond

    Ben, this isn’t even everything! A few days after domestic familiarization flights began, before the long haul launch, this particular aircraft was also involved in an incident with a jetbridge and had the L2 door pushed out of alignment. Spent a day or two out of service getting the door fixed. Brutal start.

    1. 1990 Guest

      "On the boats, (but not) on the planes... they're coming to America!" -- Neil Diamond

  14. Rhys Guest

    I see Charleston continues to deliver exquisitely manufactured Dreamliners, then! I wonder if United can claim compensation from Boeing.

    1. PeteAU Guest

      Indeed. These aren't maintenance issues, the aircraft is brand new.

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LadyOlives Guest

Made in America.

3
BenjaminKohl Diamond

Ben, this isn’t even everything! A few days after domestic familiarization flights began, before the long haul launch, this particular aircraft was also involved in an incident with a jetbridge and had the L2 door pushed out of alignment. Spent a day or two out of service getting the door fixed. Brutal start.

2
AeroB13a Guest

The silence of the Boeing fanboys is deafening! Perhaps they are sick to their back teeth of attempting to defend the indefensible?

1
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