Air India says no issues found in Boeing 787, Boeing 737 fuel control switches

Air India announced on Tuesday that it has completed comprehensive precautionary inspections of the fuel control switch locking mechanisms across its entire fleet of Boeing 787 and 737 aircraft. The airline reported that no issues were detected during these inspections, which commenced voluntarily on July 12th and were completed within the timeframe set by India's aviation regulator.

These inspections were prompted by the ongoing investigation into the tragic Air India flight AI171 crash on June 12, 2025, a Boeing 787 jetliner that crashed shortly after takeoff from Ahmedabad en route to London Gatwick. The incident resulted in the deaths of 241 of the 242 people on board and 19 on the ground.

The Aircraft Accident Investigation Bureau (AAIB) of India is focusing its probe on the aircraft's fuel control switches, which are vital components that regulate fuel flow to the engines, enabling pilots to start, shut down, or manually intervene during in-flight engine failures. A final report from the AAIB is anticipated within a year of the incident.

A preliminary report released by the AAIB earlier in July revealed that the fuel control switches for both engines of the crashed Boeing 787 had almost simultaneously flipped from 'run' to 'cutoff' positions shortly after takeoff, leading to a loss of engine power. The report also referenced a 2018 FAA advisory that had urged operators of various Boeing models, including the 787, to inspect the locking mechanism on these fuel cutoff switches to prevent unintentional movement.

Despite the AAIB's preliminary findings, the FAA and Boeing have privately communicated that the fuel switch locks on Boeing planes are safe. Reuters, citing a source, also reported last week that the cockpit voice recording from the ill-fated Air India flight suggested the captain had cut fuel to the engines, though the AAIB maintains it is too early to draw definitive conclusions.

Air India operates a fleet of Boeing 787 twin-aisle jets for its long-haul routes, while its low-cost subsidiary, Air India Express, utilizes Boeing 737 single-aisle jets. Following Air India's voluntary checks, India's aviation regulator mandated similar inspections for all domestic carriers, a directive that subsequently led some foreign airlines and regulators to follow suit.