In the wake of the tragic Air India Flight AI171 crash in Ahmedabad on June 12, 2025, which claimed 260 lives, India's Directorate General of Civil Aviation (DGCA) has taken immediate action to ensure the safety of Boeing aircraft operating in the country. The aviation regulator has directed all airlines to conduct urgent inspections of the fuel switch locking systems on Boeing 787 and 737 aircraft, with a deadline of July 21, 2025, for the completion of these checks.
The DGCA's directive follows the release of a preliminary report by the Aircraft Accident Investigation Bureau (AAIB) concerning the Air India crash. The report revealed that the fuel control switches in the Boeing 787 Dreamliner's cockpit had mysteriously moved from the "run" to the "cutoff" position just before impact, shutting off fuel supply to both engines. This caused the engines to shut down within one second of each other, leading to an immediate loss of altitude.
The DGCA's order highlights intensified scrutiny of Boeing's aircraft, with a focus on the fuel control switch locking mechanisms. The directive mandates a thorough inspection regime for specific Boeing models to address any potential vulnerabilities in these mechanisms. The regulator has asked the airlines to submit inspection plans and reports after the accomplishment of the inspection to the concerned regional office. The order applies to B737 and 787, which have fuel-control switches made by Honeywell.
The FAA had issued a service bulletin in 2018 addressing this component, but it remains uncertain whether the affected aircraft had undergone the recommended updates. Air India informed investigators that the recommended inspections under the FAA bulletin were not conducted, as the notice was classified as “non-mandatory guidance” rather than a compulsory airworthiness directive. Despite this, the AAIB report clarified that maintenance records for the aircraft showed no reported defects linked to the fuel control switch, either before or after throttle control module replacements in 2019 and 2023.
While the investigation is ongoing, both the FAA and Boeing have maintained that the current design of the fuel shutoff switches does not present an immediate safety risk. The FAA's internal Continued Airworthiness Notification affirmed that the fuel switch locks are safe and do not justify grounding aircraft or mandating repairs at this time. However, the agency has indicated that it may revise its guidance based on the final findings of the Indian investigation. Boeing has pledged full cooperation with investigators and is conducting its own review of the switch mechanism.
The Air India Flight 171 crash is the deadliest aviation accident in a decade. The incident has raised concerns about existing safety protocols and cockpit procedures. The AAIB is leading the probe into the crash, with experts from Boeing, the United States, and the United Kingdom also participating. The preliminary report indicated that the aircraft was airworthy, with its Airworthiness Review Certificate valid until May 2026, and that routine maintenance had been carried out.
In the wake of the tragedy, pilot groups have rejected claims of human error, with the Indian Commercial Pilots Association (ICPA) and the Airline Pilots' Association of India (ALPA India) issuing statements after the release of the initial findings. Air India CEO Campbell Wilson has urged against premature conclusions, stating that the probe is far from over.
The DGCA's directive for mandatory inspections reflects a commitment to passenger safety and transparency. As the investigation continues, the aviation industry is focused on understanding the cause of the Air India crash and implementing measures to prevent similar incidents in the future.
