American Airlines Flagship New Boeing 787 Faces Multiple Technical Issues

DALLAS— American Airlines (AA) is once again dealing with operational disruptions following the grounding of multiple Boeing 787-9 aircraft.

The latest issue involves a technical defect affecting cabin lighting systems, resulting in flight delays and equipment changes. This results in increasing maintenance demands across the airline’s wide-body fleet.

The problem, which came to light over the past month, centers on a defective wire harness that interferes with the interior lighting systems of the aircraft. While not a safety hazard in itself, the defect has required affected planes to be pulled from service to avoid further complications.

One such aircraft, registered as N842A, has already been grounded due to this issue. The case follows earlier disruptions with another 787-9, N846AN, which faced both wiring and door seal problems. These issues add to concerns about building consistency in Boeing’s long-haul product line.

Photo: Clément Alloing

American 787 Faces Challenges

American Airlines had deployed its 787-9s on key transcontinental and international routes. The aircraft operates domestic flights as well, such as Chicago O’Hare to Los Angeles. American deployed this Boeing variant for long-haul destinations in Europe and Asia as well.

The aircraft is a critical part of the airline’s widebody fleet, offering higher capacity and improved cabin features compared to older jets.

However, the grounding has forced American to switch the operating aircraft of a few routes onto alternate aircraft types, such as the 787-8 or 777-200ER. This leads to disrupting travel plans and creating inconsistencies in the passenger experience.

While American Airlines has not released an official comment, the absence of these aircraft from scheduled operations has been reflected in flight tracking data, with last-minute aircraft swaps and reroutes becoming more common on affected routes.

Photo: Anna Zvereva | Flickr

Reliability Concerns with the 787 Program

The Boeing 787 family has faced recurring technical setbacks since its introduction. Its most notable grounding occurred in 2013 when a series of lithium-ion battery malfunctions led to a temporary global halt of operations.

Following this, airlines reported other complications in the next few years. Airlines faced problems such as cracks in composite fuselage sections, issues with engine durability, and production flaws linked to suppliers.

The 787-9 variant, which entered service in 2014, was designed to offer a longer range and increased seating over the base model. However, production has been periodically interrupted due to fuselage assembly problems at Spirit AeroSystems and quality control inconsistencies at Boeing’s South Carolina facility.

Earlier in 2025, a Boeing 787-8 operated by American Airlines (N819AN) diverted back to Amsterdam due to hydraulic issues and was forced to land at a higher speed, raising further questions about the fleet’s reliability.

These events have drawn renewed attention to ongoing technical challenges facing the Dreamliner program. The airline also has a growing backlog of aircraft awaiting delivery modifications.

Photo: Alan Wilson | Flickr

Impact on American Airlines’ Schedules

Travelers booked on affected flights have voiced frustration, with some sharing stories of last-minute rebookings on social media.

Passengers expecting the newer 787-9 cabin features, such as larger windows, quieter interiors, and modern business-class seating, have expressed dissatisfaction after being moved to older aircraft.

While American’s 787-8s offer similar layouts, the newer -9s feature the carrier’s refreshed premium experience, particularly for long-haul travelers. There are also speculations about delays in American’s fleet expansion, with the airline operating over 55 Dreamliners, including 37 787-8s and 22 787-9s.

Flight cancellations and changes have also affected hub operations at Chicago O’Hare, Los Angeles, and Dallas-Fort Worth. These airports see the 787-9s regularly used by American Airlines.

Ground staff and maintenance teams are reportedly working under tight timelines to inspect and rectify the issues. However, the timeline for resolution remains unclear.

Photo: Cado Photo

What Lies Ahead

The latest groundings will further complicate American Airlines’ fleet planning now. This comes at a time when transatlantic and transpacific demand is growing. The carrier operates a total of 59 Dreamliners, with 22 being the -9 variant.

American may need to delay upcoming deployments or adjust aircraft allocations on busy routes. Again, this depends on how widespread the wiring defect is across the fleet.

The long-term reliability of the 787 will remain a major concern. This won’t be limited only to American Airlines but also to other global operators.

Many airlines are flying aging or frequently updated variants of the aircraft. For now, the airline’s booking engine will need to be monitored. There can be potential last-minute changes, especially on routes that are traditionally served by the 787-9.

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