Washington, DC, July 14 - In the wake of a tragic Air India Boeing 787-8 crash that claimed 260 lives, the U.S. Federal Aviation Administration (FAA) and Boeing have issued notifications affirming the safety of the aircraft’s fuel switch locks, according to a document obtained by Reuters and corroborated by four sources familiar with the matter. The crash, which occurred last month shortly after takeoff from Ahmedabad, India, prompted intense scrutiny of the aircraft’s engine fuel cutoff switches, particularly after a preliminary report by India’s Aircraft Accident Investigation Bureau (AAIB) raised questions about their role in the incident. The FAA’s Continued Airworthiness Notification, issued on July 11, 2025, stated that the fuel control switch design, including its locking mechanism, does not constitute an unsafe condition warranting an Airworthiness Directive for any Boeing models, including the 787. Boeing reinforced this position in a Multi-Operator Message to airlines, advising no immediate action, as confirmed by two sources.
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The AAIB’s preliminary report, released on July 12, 2025, revealed that the fuel switches on the ill-fated Air India Flight 171, bound for London’s Gatwick Airport, were moved from the “run” to “cutoff” position almost simultaneously just seconds after takeoff, leading to a catastrophic loss of engine power. The report noted that the aircraft’s Ram Air Turbine, a backup power source, had deployed, indicating a severe systems failure. This finding shifted focus to the fuel switches, which are designed to regulate fuel flow to the engines and are equipped with a locking feature to prevent accidental movement. Aviation experts have emphasized that these lever-lock switches, a standard safety feature since the 1950s, require deliberate action—lifting against strong spring tension before flipping—making accidental disengagement highly unlikely.
The investigation also referenced a 2018 FAA Special Airworthiness Information Bulletin, which recommended, but did not mandate, inspections of the fuel switch locking feature on several Boeing models, including the 787, due to concerns about potential disengagement. Air India reported that it did not conduct these inspections, as they were advisory, not mandatory. However, maintenance records indicate that the throttle control module, which includes the fuel switches, was replaced in 2019 and 2023 on the crashed aircraft, with no defects reported. The AAIB confirmed that all applicable airworthiness directives and service bulletins were complied with, and fuel samples from the refwarden tanks were found to be satisfactory, ruling out contamination as a cause.
The preliminary report’s findings have sparked debate, with questions lingering about how the switches were moved. Cockpit voice recordings captured one pilot asking the other why the cutoff was initiated, to which the response was a denial of action, deepening the mystery. No mechanical failures have been identified, and the recent announcements from the FAA and Boeing suggest confidence in the switch design. The final report, expected in the coming months, will likely clarify the interplay of human and mechanical factors in this tragedy.