A part that broke on a UPS plane that crashed in Kentucky failed 4 times on other planes years ago

Boeing warned plane owners in 2011 about a broken part that contributed to a UPS plane crash that killed 15 last year but at that point the plane manufacturer didn't believe it threatened safety, the National Transportation Safety Board said Wednesday.

The UPS plane crashed in November 2025 shortly after taking off in Louisville, Kentucky, when the left engine flew off the wing as the plane rolled down the runway. Three pilots on the plane that was headed for Hawaii were killed along with 12 more people on the ground near Louisville’s Muhammad Ali International Airport.

The NTSB said Wednesday that Boeing had documented in 2011 there were four previous failures of a part that helps secure the MD-11's engines to the wings on three different planes, but at that point the plane manufacturer “determined it would not result in a safety of flight condition.” These planes were actually built by McDonnell Douglas, which was later bought by Boeing.

The NTSB previously said investigators found cracks in some of the parts that held the engine to the wing. Those cracks hadn’t been caught in regular maintenance done on the plane, which raised questions about the adequacy of the maintenance schedule. The last time those key engine mount parts were examined closely was in October 2021, and the plane wasn’t due for another detailed inspection for roughly 7,000 more takeoffs and landings.

It’s not clear when the cracks started to develop in the parts that helped hold the engine on the wing, but this crash is reminiscent of a 1979 crash in Chicago when the left engine flew off an American Airlines DC-10 during takeoff, killing 273 people. The DC-10 was the predecessor of the MD-11.

That previous crash led to the worldwide grounding of 274 DC-10s. The airline workhorse was allowed to return to the skies because the NTSB determined that maintenance workers damaged the plane that crashed while improperly using a forklift to reattach the engine. That meant the crash wasn’t caused by a fatal design flaw even though there had already been a number of accidents involving DC-10s.

But former FAA and NTSB crash investigator Jeff Guzzetti said that a service bulletin McDonnell Douglas issued in 1980 did identify failures of the spherical bearing race as a “safety of flight condition” so it's surprising that Boeing didn't call it that in 2011. He said that American had removed the engine of that plane so it could inspect that bearing.

“I just think it raises questions regarding the adequacy of the severity of the 2011 service letter, and it also raises questions about how UPS incorporated that information and acted upon it,” Guzzetti said.

The service bulletin that Boeing issued didn't require plane owners to make repairs like an FAA airworthiness directive would, and the agency didn't issue such a directive.

Former federal crash investigator Alan Diehl said the notice from Boeing recommended replacing the bearings with a redesigned part that was less likely to fail, but it still allowed operators to replace defective bearings with another older bearing that had demonstrated it was prone to failing.

“As the investigation continues, the NTSB will have to address whether this service bulletin was an adequate solution to a known problem which could have had catastrophic results,” Diehl said. “The UPS crash highlights the need for increased maintenance measures on older airframes.”

NTSB didn't say whether there had been additional documented failures of the spherical bearing race since 2011. Investigators found that part broken into two pieces after the UPS crash, and the lugs that held that part were cracked.

Photos released by the NTSB of the Nov. 4 crash show flames erupting as the rear of the engine starting to detach before it flew up and over the wing. Then the wing was engulfed by fire as the burning engine flew above it.

The factual report released Wednesday doesn’t state what caused the engine to fly off, but it's clear that investigators are focused on the failure of this bearing. The ultimate conclusion won't come though until the NTSB's final report, which usually doesn't come until more than a year after a crash.

But the report will undoubtedly be cited in the first lawsuit over the crash, filed last month, and subsequent ones. They will be investigating what Boeing knew at the time and what UPS did in response to this 2011 bulletin.

“I think that this even further demonstrates that there was warning signs that predated the crash that any reasonable organization should have utilized to make sure that the Louisville crash didn’t happen,” said attorney Brad Cosgrove of the Clifford Law firm, which filed the first lawsuit.

The report does make clear that neither of the plane's two other engines were on fire before the crash. Some experts had previously speculated that debris from the left engine might have damaged the engine on the tail.

Boeing, UPS and the Federal Aviation Administration are limited on what they can say while the NTSB investigation is ongoing, so they all declined to comment on Wednesday's report. Boeing and UPS both expressed condolences to the families that lost loved ones in the crash.

“We remain profoundly saddened by the Flight 2976 accident,” UPS spokesperson Jim Mayer said. “Our thoughts continue to be with the families and Louisville community who are grieving, and we remain focused on the recovery effort,” Mayer said.

The 34-year-old MD-11 plane only got 30 feet (9.1 meters) off the ground before crashing into several industrial buildings just past the runway and generating a massive fireball that could be seen for miles. Dramatic videos of the crash showed the plane on fire as it plowed into buildings and released a massive plume of smoke.

Airlines quit flying this type of plane commercially years ago because it isn't as efficient as newer models, but they had continued to fly for cargo carriers like UPS and FedEx and a few of these planes were also modified for use in firefighting. All the MD-11s that had been in use and 10 related DC-10s have been grounded since the crash.

Cosgrove said he thinks it will eventually become clear that these MD-11s “probably should have been retired and that they had exceeded their shelf life.”

A cleanup crew detects and decontaminates water in a ditch during a tour of the UPS plane crash site, Tuesday, Jan. 13, 2026, in Louisville, Ky. (AP Photo/Jon Cherry)

Louisville Mayor Craig Greenberg speaks during a tour of the UPS plane crash site, Tuesday, Jan. 13, 2026, in Louisville, Ky. (AP Photo/Jon Cherry)

A UPS Boeing 737 takes over a destroyed truck during a tour of the UPS plane crash site, Tuesday, Jan. 13, 2026, in Louisville, Ky. (AP Photo/Jon Cherry)

FILE - This photo provided by the National Transportation Safety Board shows UPS plane crash scene on Thursday, Nov. 6, 2025 in Louisville, Ky. (NTSB via AP, File)

FILE - Plumes of smoke rise from the area of a UPS cargo plane crash at Louisville Muhammad Ali International Airport, on Tuesday, Nov. 4, 2025, in Louisville, Ky. (AP Photo/Jon Cherry, File)

WASHINGTON (AP) — Senate Republicans voted to dismiss a war powers resolution Wednesday that would have limited President Donald Trump’s ability to conduct further attacks on Venezuela after two GOP senators reversed course on supporting the legislation.

Trump put intense pressure on five Republican senators who joined with Democrats to advance the resolution last week and ultimately prevailed in heading off passage of the legislation. Two of the Republicans — Sens. Josh Hawley of Missouri and Todd Young of Indiana — flipped under the pressure.

Vice President JD Vance had to break the 50-50 deadlock in the Senate on a Republican motion to dismiss the bill.

The outcome of the high-profile vote demonstrated how Trump still has command over much of the Republican conference, yet the razor-thin vote tally also showed the growing concern on Capitol Hill over the president’s aggressive foreign policy ambitions.

Democrats forced the debate after U.S. troops captured Venezuelan leader Nicolás Maduro in a surprise nighttime raid earlier this month

“Here we have one of the most successful attacks ever and they find a way to be against it. It’s pretty amazing. And it’s a shame,” Trump said at a speech in Michigan Tuesday. He also hurled insults at several of the Republicans who advanced the legislation, calling Sen. Rand Paul of Kentucky a “stone cold loser” and Sens. Lisa Murkowski of Alaska and Susan Collins of Maine “disasters.” Those three Republicans stuck to their support for the legislation.

Trump’s latest comments followed earlier phone calls with the senators, which they described as terse. The president’s fury underscored how the war powers vote had taken on new political significance as Trump also threatens military action to accomplish his goal of possessing Greenland.

The legislation, even if it had cleared the Senate, had virtually no chance of becoming law because it would eventually need to be signed by Trump himself. But it represented both a test of GOP loyalty to the president and a marker for how much leeway the Republican-controlled Senate is willing to give Trump to use the military abroad. Republican angst over his recent foreign policy moves — especially threats of using military force to seize Greenland from a NATO ally — is still running high in Congress.

Hawley, who helped advance the war powers resolution last week, said Trump’s message during a phone call was that the legislation “really ties my hands.” The senator said he had a follow-up phone call with Secretary of State Marco Rubio Monday and was told “point blank, we’re not going to do ground troops.”

The senator added that he also received assurances that the Trump administration will follow constitutional requirements if it becomes necessary to deploy troops again to the South American country.

“We’re getting along very well with Venezuela,” Trump told reporters at a ceremony for the signing of an unrelated bill Wednesday.

As senators went to the floor for the vote Wednesday evening, Young also told reporters he was no longer in support. He said that he had extensive conversations with Rubio and received assurances that the secretary of state will appear at a public hearing before the Senate Foreign Relations Committee.

Young also shared a letter from Rubio that stated the president will “seek congressional authorization in advance (circumstances permitting)” if he engaged in “major military operations” in Venezuela.

The senators also said his efforts were also instrumental in pushing the administration to release Wednesday a 22-page Justice Department memo laying out the legal justification for the snatch-and-grab operation against Maduro.

That memo, which was heavily redacted, indicates that the administration, for now, has no plans to ramp up military operations in Venezuela.

“We were assured that there is no contingency plan to engage in any substantial and sustained operation that would amount to a constitutional war,” according to the memo signed by Assistant Attorney General Elliot Gaiser.

Trump has used a series of legal arguments for his campaign against Maduro.

As he built up a naval force in the Caribbean and destroyed vessels that were allegedly carrying drugs from Venezuela, the Trump administration tapped wartime powers under the global war on terror by designating drug cartels as terrorist organizations.

The administration has claimed the capture of Maduro himself was actually a law enforcement operation, essentially to extradite the Venezuelan president to stand trial for charges in the U.S. that were filed in 2020.

Paul criticized the administration for first describing its military build-up in Caribbean as a counternarcotics operation but now floating Venezuela’s vast oil reserves as a reason for maintaining pressure.

"The bait and switch has already happened,” he said.

Lawmakers, including a significant number of Republicans, have been alarmed by Trump’s recent foreign policy talk. In recent weeks, he has pledged that the U.S. will “run” Venezuela for years to come, threatened military action to take possession of Greenland and told Iranians protesting their government that “ help is on its way.”

Senior Republicans have tried to massage the relationship between Trump and Denmark, a NATO ally that holds Greenland as a semi-autonomous territory. But Danish officials emerged from a meeting with Vance and Rubio Wednesday saying a “fundamental disagreement” over Greenland remains.

"What happened tonight is a roadmap to another endless war," Senate Democratic leader Chuck Schumer said at a news conference following the vote.

More than half of U.S. adults believe President Donald Trump has “gone too far” in using the U.S. military to intervene in other countries, according to a new AP-NORC poll.

House Democrats have also filed a similar war powers resolution and can force a vote on it as soon as next week.

Last week's procedural vote on the war powers resolution was supposed to set up hours of debate and a vote on final passage. But Republican leaders began searching for a way to defuse the conflict between their members and Trump as well as move on quickly to other business.

Once Hawley and Young changed their support for the bill, Republicans were able to successfully challenge whether it was appropriate when the Trump administration has said U.S. troops are not currently deployed in Venezuela.

“We’re not currently conducting military operations there,” said Senate Majority Leader John Thune in a floor speech. “But Democrats are taking up this bill because their anti-Trump hysteria knows no bounds.”

Democratic Sen. Tim Kaine, who has brought a series of war powers resolutions this year, accused Republicans of burying a debate about the merits of an ongoing campaign of attacks and threats against Venezuela.

"If this cause and if this legal basis were so righteous, the administration and its supporters would not be afraid to have this debate before the public and the United States Senate," he said in a floor speech.

Associated Press writers Josh Goodman, Lisa Mascaro, Mary Clare Jalonick and Joey Cappelletti in Washington and Bill Barrow in Atlanta contributed to this report.

President Donald Trump speaks during a meeting with oil executives in the East Room of the White House, Friday, Jan. 9, 2026, in Washington. (AP Photo/Evan Vucci)

Sen. Josh Hawley, R-Mo., talks with reporters outside the Senate chamber during a vote at the Capitol, Tuesday, Jan. 6, 2026, in Washington. (AP Photo/Rod Lamkey, Jr.)

Sen. Rand Paul, R-Ky., speaks with reporters at the Senate Subway on Capitol Hill, Thursday, Jan. 8, 2026, in Washington. (AP Photo/Mariam Zuhaib)

Senate Majority Leader John Thune, R-S.D., speaks during a news conference at the Capitol, Tuesday, Jan. 13, 2026, in Washington. (AP Photo/Rod Lamkey, Jr.)