Executive Summary
- UPS completed the retirement of its MD-11 fleet in Q4 2025 following a fatal crash in Louisville.
- The November 2025 accident killed 14 people after an engine detached during takeoff.
- NTSB investigators found undetected fatigue cracks in the aircraft’s engine mounts.
- The FAA issued an Emergency Airworthiness Directive grounding MD-11s for inspection.
- UPS is accelerating its fleet modernization with new Boeing 767 freighters.
UPS has confirmed the permanent retirement of its entire fleet of McDonnell Douglas MD-11 cargo aircraft following a catastrophic crash in Louisville, Kentucky, in late 2025 that resulted in 14 fatalities and triggered a federal safety investigation. During its fourth-quarter earnings update, the logistics giant announced that it completed the phaseout of the tri-jet freighter fleet during the fourth quarter of 2025, taking a $137 million after-tax non-cash write-off associated with the decision.
The strategic shift comes in the wake of the tragedy involving UPS Flight 2976. According to the National Transportation Safety Board (NTSB), the aircraft, registered as N259UP, crashed shortly after departing Louisville Muhammad Ali International Airport (SDF) for Honolulu in November 2025. Investigators confirmed that the MD-11’s left engine detached from the wing during takeoff rotation. The aircraft reached an altitude of only 30 feet before impacting a UPS Supply Chain Solutions warehouse and other industrial facilities near the runway. The accident claimed the lives of the three crew members and 11 individuals on the ground, while injuring another 23 people.
Preliminary findings released by the NTSB identified structural failures in the aircraft’s engine pylon. Investigators discovered fatigue cracks in the aft mount lugs of the left pylon that were not detected during the aircraft’s last major inspection in 2021. The agency’s report detailed that the failure involved both fatigue cracking and overload, causing the engine to separate and traverse over the fuselage before igniting a massive fire that consumed the aircraft.
In response to the incident, the Federal Aviation Administration (FAA) issued an Emergency Airworthiness Directive on November 14, grounding MD-11 operations for immediate inspections. The directive affected other major operators, including FedEx and Western Global Airlines. UPS stated it had already grounded its fleet, which constituted 9% of its capacity, prior to the FAA mandate “out of an abundance of caution.” To replace the lost capacity, UPS CEO Carol Tomé confirmed the company is accelerating its modernization plans by integrating new, more efficient Boeing 767 freighters.
Regulatory and Operational Implications
The retirement of the MD-11 fleet by a major operator like UPS marks a significant shift in the global air cargo landscape, signaling the end of an era for the iconic tri-jet in mainline commercial service. The incident has intensified regulatory scrutiny regarding the structural integrity of aging airframes, particularly focusing on engine-to-wing attachment points. The NTSB’s discovery of undetected fatigue cracks highlights potential gaps in legacy maintenance protocols, likely prompting stricter inspection mandates for remaining heavy-lift operators. As the investigation continues, the industry anticipates further safety recommendations aimed at preventing similar structural failures in older cargo aircraft.
