NEW DELHI/WASHINGTON D.C. – July 14, 2025 – In the wake of the tragic Air India Boeing 787-8 crash last month, which claimed 260 lives, a preliminary investigation report from India’s Aircraft Accident Investigation Bureau (AAIB) has raised serious questions about the aircraft’s engine fuel cutoff switches. This has prompted the U.S. Federal Aviation Administration (FAA) and Boeing to issue private notifications affirming the safety of their fuel switch locking mechanisms across various Boeing models.
The AAIB’s preliminary report, released on July 11, revealed a critical finding: the fuel control switches for both engines on the ill-fated Air India Flight 171 transitioned from “RUN” to “CUTOFF” position within seconds of takeoff. This abrupt fuel cutoff led to the loss of thrust and subsequent engine shutdown, ultimately causing the aircraft to crash. The cockpit voice recorder reportedly captured a chilling exchange between the pilots, with one asking the other why he had cut off the fuel, to which the co-pilot replied that he had not.
FAA and Boeing Stand by Design
In response to these findings, the FAA issued a “Continued Airworthiness Notification” to civil aviation authorities globally on July 11. This notification, seen by Reuters, stated that “although the fuel control switch design, including the locking feature, is similar on various Boeing airplane models, the FAA does not consider this issue to be an unsafe condition that would warrant an Airworthiness Directive on any Boeing airplane.”
Boeing, for its part, has echoed the FAA’s position in a “Multi-Operator Message” circulated to airlines. Sources familiar with the matter indicate that Boeing is not recommending any additional action in response to the incident, asserting that the fuel switch locks are safe.
A 2018 Advisory and Unanswered Questions
The AAIB’s preliminary report notably referenced a 2018 FAA Special Airworthiness Information Bulletin (SAIB). This advisory had recommended, but did not mandate, that operators of several Boeing models, including the 787, inspect the locking feature of their fuel cutoff switches to prevent inadvertent movement.
The report pointed out that Air India had not conducted these recommended inspections, as the FAA advisory was not compulsory. While maintenance logs showed that the aircraft’s throttle control module, which houses the fuel switches, had been replaced twice (in 2019 and 2023), the reason for these replacements was not linked to the fuel control switches themselves.
Pilot Union Raises Concerns
The preliminary report’s findings have naturally sparked a contentious debate. While the FAA and Boeing maintain the safety of the fuel switch design, the revelation of the engine cutoff, coupled with the pilots’ apparent confusion, has led to speculation. The Indian pilots’ association (ALPA India) has issued a strong statement rejecting any presumption of pilot error and has demanded observer status in the ongoing investigation to ensure a “fair, fact-based inquiry.”
The fuel control switches are designed with protective brackets and a spring-loaded locking mechanism that typically requires a deliberate two-step action – lifting the switch over a metal stop before pulling it down – to move it from “RUN” to “CUTOFF.” The AAIB report did not clarify how the switches could have transitioned to the “CUTOFF” position shortly after takeoff, an action usually reserved for engine shutdown after landing or in severe emergencies.
As the investigation continues, all eyes will remain on the AAIB’s final report to shed more light on this perplexing and tragic incident. The focus will be on understanding whether the engine cutoff was a result of a mechanical anomaly, an unforeseen design flaw, or human factors, and what implications it holds for aviation safety worldwide.
