Boeing’s last 787-8 test airplane leaves a lasting legacy as it retires to the Arizona desert this week. While it has been pushed to and beyond the limits any 787 Dreamliner might face in service, it established the performance, safety and maintenance standards that guide every 787 in operation today.
“To the casual observer it looks like an old airplane, but it’s always been the future,” said Capt. Heather Ross, who served as the airplane’s first chief project pilot and was at the controls one last time for its final takeoff from Boeing Field in Seattle.
ZA004 takes off for its final flight from Boeing Field in Seattle. (© Boeing photo)
Capt. Heather Ross and Capt. Craig Bomben, who flew together on ZA004’s first flight, led the final flight crew. They were joined by Capt. Chris Caps, who served as an engineering systems operator on the airplane’s first flight and is now a Boeing test pilot, and Elmo Valdez, a flight analyst who has supported ZA004 for many years.
For the many employees who have supported the airplane, its departure is a bittersweet milestone they’ve been bracing for.
“Sixteen years of service with The Boeing Company — that’s a legacy few test airplanes achieve,” said John Murphy, the 787 program’s chief project engineer.
- He added that the decision to retire ZA004 came as the airplane approached maintenance thresholds that were no longer cost-effective given the maturity of the test program and fleet.
At a Jan. 30 event, employees reflected on ZA004’s retirement and signed a guest log that flew on the airplane’s final flight. It will be archived by Boeing. (© Boeing video)
A lasting legacy: ZA004 entered Boeing’s flight test program on Feb. 24, 2010, registered as N7874. Over the last 16 years, it has flown more than 670 test flights over more than 2,250 flight hours and visited more than 30 global airports. Its contributions include:
- Performing the 1,000th 787 flight in 2011.
- Supporting certification of all Rolls‑Royce 787 engine variants, including the Trent 1000 XE in 2025.
- Serving as Boeing’s second ecoDemonstrator in 2014 to test more than 25 technologies that improved efficiency and reduced emissions.
- Flying the first flight to validate upgrades to the airplane’s power distribution system software after an in‑flight electrical incident on ZA002 paused the flight test program.
“Test airplanes, like ZA004, don’t just prove what’s possible. They make the future real by translating design concepts into everyday safety, efficiency and capability,” said Murphy. “ZA004’s legacy lives on in every 787 Dreamliner flying today and those yet to be delivered.”
What’s next: The airplane’s original air‑traffic control callsign, “Boeing 004,” was used again for the airplane’s final flight to Pinal Airpark in Marana, Arizona, a long‑term storage and reclamation facility.
- There, ZA004, will continue to contribute to learning and development on the 787, supporting BCA’s 2026 priority to innovate for productivity and performance.
- Some parts will be used for training and research.
- Other parts will be distributed as replacements or spares through Boeing Global Services.
“This airplane embodies the reason why many of us joined Boeing,” Murphy said. “We’re here because we love airplanes and because we get to work on awe-inspiring innovations.”