🚨 Hidden Failures in Modern Jets: When “It Can’t Happen” Happens

🛫 Can a Boeing 787 Engine Fail?

Yes — it can. Not in the way people imagine fireballs in the sky, but in a rare event called Uncommanded High Thrust (UHT). This means the engine gives out full power independently, without pilot input.

The FAA has acknowledged that certain rare situations, like high crosswinds during takeoff or landing, can lead to the aircraft becoming uncontrollable. While Boeing has added systems to manage this on the ground automatically, it doesn’t always cover airborne scenarios.

➡️ FAA granted Boeing a conditional exemption from the “no single failure” rule, trusting the extremely low probability (less than 1 in 10 million hours) and Boeing’s plan to monitor and improve systems.

Bottom Line: It can happen. The risk is very low, but it exists — and history reminds us that unlikely does not mean impossible.

🛩️ “Boeing: Inboard Flap Asymmetry B757 Cannot Happen… Happened!”

In the 1990s, American Airlines was testing its newly acquired Boeing 757 in a simulator. A scenario involving inboard flap asymmetry (one flap failing to extend or retract properly) created an irrecoverable situation.

When Boeing was informed, they replied:

“Yes, the simulator is correct, but this cannot happen in the real aircraft because of built-in safety systems.”

But then — it did happen. Not once, but twice on other carriers:

• Once during the flight
• Once on the ground

In both cases, sharp decision-making by the captain — quickly retracting flaps — saved the aircraft from disaster.
But it raised a chilling question:

“What if the flaps didn’t retract?”

American Airlines introduced a procedure to recover from the asymmetry, but the residual risk remains.

📜 Airworthiness Directive (AD)

The FAA later issued a directive requiring repetitive inspections for wear in flap torque tube couplings on B757s. But that only came after the near-misses.

🧠 What’s the Lesson?

Manufacturers and regulators often assure that “this can’t happen”, based on engineering redundancy and probability. But real-world experience — from engine control failures to flap asymmetry — tells a different story.

When simulations, pilots, or incidents show otherwise, it’s time to listen.

At Safety Matters Foundation, we believe in proactive risk recognition, transparency, and continuous vigilance — not just compliance.

📽️ Watch more: American Airlines simulator video