Air India Crash: FAA Advisory Over Fuel Switch Locking in Spotlight
Union Minister Amit Shah at the Air India plane crash site (Image Amit Shah, X)
Report Points to Advisory Maintenance Gaps, Possible Structural Failures in Air India Flight AI171 Tragedy
By KUMAR VIKRAM
NEW DELHI, July 12, 2025 — The preliminary report into the crash of Air India Flight AI171 has revealed that while the aircraft met all regulatory maintenance and airworthiness requirements, an earlier advisory issued by the US Federal Aviation Administration (FAA) in 2018 regarding the fuel control switch locking mechanism was never acted upon — a detail now under close scrutiny.
The Boeing 787-8 Dreamliner (registration VT-ANB), operating from Ahmedabad to London Gatwick on June 12, crashed moments after take-off following the simultaneous and unexplained shutdown of both engines. All 230 passengers and crew on board are presumed dead, with the aircraft completely destroyed in a high-impact collision with buildings near the airport, followed by a fire.
FAA Advisory Flagged Potential Fuel Switch Risk in 2018
According to the report, the FAA had issued Special Airworthiness Information Bulletin (SAIB No. NM-18-33) in December 2018, warning operators of Boeing aircraft about the potential disengagement of the fuel control switch locking feature. This component, designed to prevent inadvertent shutdown of engines during flight, shares its design across several Boeing models, including the part installed on VT-ANB (Part No. 4TL837-3D).
However, the FAA had not categorized the issue as an “unsafe condition” that would warrant a mandatory airworthiness directive (AD). As a result, airlines, including Air India, were not legally bound to perform inspections or retrofits based on the bulletin.
Air India confirmed that no inspection related to the locking mechanism was carried out on VT-ANB, given the advisory nature of the notice. Maintenance records show the aircraft’s throttle control module was replaced twice — in 2019 and 2023 — but those actions were unrelated to the fuel control switch.
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Maintenance Compliant, But Tragedy Strikes Months Before D-Check
Investigators found that the aircraft had undergone its last major line checks (L1-1 and L1-2) well within the approved schedule and was due for its comprehensive D-check only in December 2025. The aircraft had accumulated 38,504 hours and 7,255 cycles at the time of the crash.
Both engines were recently installed:
- Left engine (ESN956174): Installed on May 1, 2025
- Right engine (ESN956235): Installed on March 26, 2025
Maintenance logs indicate that the aircraft had four active Category C MEL (Minimum Equipment List) items valid until June 19, 2025. These included minor systems such as the flight deck visual surveillance system, airport map function, and core network printer. A Category A MEL concerning nitrogen generation performance was also active, valid until June 20. All MEL items were within permissible timeframes and unrelated to engine performance.
All Regulatory Requirements Met
Importantly, the aircraft and both engines were compliant with all applicable Airworthiness Directives (ADs) and Alert Service Bulletins at the time of the accident. No open defects pertaining to the fuel control switch had been reported since 2023.
Despite this, investigators are now examining whether the fuel control switch locking mechanism — and the failure to inspect or retrofit it following the 2018 advisory — could have played a role in the simultaneous transition of both engine fuel switches from RUN to CUTOFF during initial climb.
Widespread Structural Devastation on Ground
The report also details the devastating impact on the ground. The aircraft struck five buildings in the Army Medical Corps area and surrounding structures, causing severe structural and fire damage. Wreckage was scattered over 765 feet, with major components — including the engines, wings, landing gears, and fuselage — disintegrating and igniting upon impact.
What Comes Next
With growing focus on a potential system anomaly — possibly electrical or mechanical — that triggered both engines to shut down, investigators are now coordinating with Boeing and international aviation bodies to examine the design and behaviour of the fuel control switches, autothrottle wiring, and related cockpit systems.
A full accident report is expected in the coming months. Meanwhile, Air India and the Ministry of Civil Aviation have pledged full cooperation with the investigation.
This is one of India’s worst aviation disasters in over a decade and has triggered renewed calls for more proactive compliance with safety advisories, even when not mandatory.
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