Following the tragic crash of Air India flight AI 171 on June 12, 2025, which resulted in the death of 270 people, investigations into the cause of the accident are ongoing. A preliminary report from India's Aircraft Accident Investigation Bureau (AAIB) indicated that the aircraft's fuel control switches unexpectedly moved to the "CUTOFF" position shortly after takeoff, causing both engines to stop functioning. These switches are critical cockpit components that regulate the flow of fuel to the engines, playing a vital role during engine start-up, in-flight operations, shutdowns, and emergencies.

Amidst the ongoing investigation, FAA Administrator Bryan Bedford has suggested that the AI 171 crash was not due to mechanical failure or accidental fuel control switch movement.

The focus on fuel control switches has prompted scrutiny of Boeing, the manufacturer of the 787-8 Dreamliner involved in the crash. Just weeks before the AI 171 disaster, the UK Civil Aviation Authority (CAA) had issued a warning regarding potential fuel system issues on Boeing aircraft. Specifically, on May 15, 2025, the CAA directed operators of five Boeing aircraft types, including the 787, to review and act upon a US Federal Aviation Administration (FAA) Airworthiness Directive (AD) related to fuel shutoff valve actuator components essential to preventing fuel leaks and engine shutdowns.

Further complicating the matter, reports indicate that the Throttle Control Module (TCM), which houses the fuel control switches, had been replaced on the crashed Air India Dreamliner in 2019 and 2023, reportedly in line with Boeing's standard schedule. The AAIB report also highlighted that Air India did not inspect the locking mechanism of the fuel cutoff switches, despite a 2018 FAA advisory recommending such checks. Air India defended its decision by stating that the advisory was non-mandatory, and therefore the airline chose not to carry out the inspections.

In response to the preliminary report and the focus on fuel control switches, the Directorate General of Civil Aviation (DGCA) in India mandated all Indian airlines to inspect the fuel switch controls of specified aircraft models by July 21, 2025, referencing the 2018 safety notice issued by the FAA. Air India announced that it had completed precautionary inspections on the locking mechanism of Fuel Control Switch (FCS) on all Boeing 787 and Boeing 737 aircraft in its fleet and that no issues were found with the said locking mechanism.

Adding another layer to the investigation, it has been noted that in AI 171, the fuel‐cutoff switches are mechanically secured to prevent accidental activation.