Seoul, July 15 - South Korea’s transport ministry has announced plans to mandate inspections of fuel control switches on all Boeing aircraft operated by its national airlines, a decision prompted by findings from a preliminary investigation into a tragic Air India crash in June 2025 that claimed 260 lives. The crash, involving a Boeing 787-8 Dreamliner, occurred shortly after takeoff from Ahmedabad, India, when the aircraft’s fuel switches unexpectedly moved from the “run” to “cutoff” position, starving the engines of fuel and leading to the disaster. This incident has raised global concerns about the safety of fuel switch locking mechanisms on Boeing jets, prompting regulatory actions and voluntary inspections by airlines worldwide.
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The South Korean directive aligns with a 2018 advisory from the U.S. Federal Aviation Administration (FAA), which recommended, but did not mandate, that operators of several Boeing models, including the 787 and 737, inspect the locking mechanisms of fuel cutoff switches to prevent accidental disengagement. The advisory followed reports of potential issues with the switches, which are designed to regulate fuel flow to the engines and are located near the thrust levers in the cockpit. In the Air India crash, preliminary data revealed that both engines’ fuel switches flipped to the cutoff position seconds after takeoff, though investigators have yet to determine the cause of this movement. The cockpit voice recorder captured confusion among the pilots, with neither claiming responsibility for altering the switch positions.
In response to the crash, India’s Directorate General of Civil Aviation (DGCA) issued an order on July 14, 2025, requiring all domestic airlines operating Boeing 737s and 787s to inspect their fuel switch locking mechanisms by July 21. Air India, at the center of the tragedy, began inspecting its Boeing 787 and 737 fleets over the weekend prior to the DGCA’s directive. A source familiar with the matter reported that approximately half of Air India’s 787s and nearly all of its 737s have been checked, with no defects identified so far. The inspections are expected to be completed within days. Other international carriers, including Etihad Airways and Singapore Airlines, have also initiated precautionary checks on their Boeing fleets, reflecting a broader industry response to the crash findings.
The Air India investigation highlighted that the airline had not conducted the FAA’s recommended inspections, as the 2018 advisory was not mandatory. Additionally, the aircraft’s throttle control module, which houses the fuel switches, had been replaced in 2019 and 2023, though these replacements were unrelated to the switches themselves. Despite Boeing and the FAA recently notifying airlines that the fuel switch locks are safe and do not require additional checks, the actions by South Korea, India, and other operators suggest a cautious approach. The inspections focus on ensuring the locking mechanisms function correctly to prevent unintended movement, a critical safety feature given the switches’ role in maintaining engine operation. This global response underscores the aviation industry’s commitment to safety in the wake of the Air India tragedy. South Korea’s mandate, alongside similar measures in India and voluntary checks by other airlines, reflects heightened scrutiny of Boeing’s fuel switch design. As investigations continue, regulators and airlines are prioritizing proactive measures to address potential vulnerabilities, even as the exact cause of the switch movement in the Air India crash remains under investigation. The outcome of these inspections may influence future regulatory standards and Boeing’s approach to fuel switch design across its aircraft models.