SUSPENSE BUILDS: FAA Flagged Fuel Switch Flaw in 2018 — Now at Center of Air India 787 Crash That Killed 260
A known mechanical flaw flagged by U.S. aviation regulators in 2018 has resurfaced at the center of the deadly Air India Flight AI171 crash.
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| Representational Image Source: erbmjha on x |
The FAA’s Special Airworthiness Information Bulletin (SAIB No. NM-18-33), issued on December 17, 2018, warned of potential disengagement of the locking feature on fuel control switches installed in multiple Boeing aircraft models — including the 787-8 Dreamliner.
“Inadvertent operation of the switch could result in an unintended consequence, such as an in-flight engine shutdown.”
— FAA SAIB NM-18-33, page 1, paragraph 2
The AAIB’s preliminary report confirms that on June 12, 2025, both engines of the Air India Boeing 787-8 shut down seconds after takeoff from Ahmedabad, after the fuel control switches were moved from “RUN” to “CUTOFF” — manually and nearly simultaneously.
Voice recordings captured the cockpit exchange:
“Why did you cutoff?”
“I didn’t.”
The aircraft lost all power and crashed just 32 seconds later into the BJ Medical College hostel compound, killing 260 people.
The FAA bulletin, based on reports from Boeing 737 operators, identified the faulty switch design — manufactured by Honeywell — as prone to accidental movement if the locking mechanism was disengaged. The switch type is used in 787 aircraft as well.
Air India had recorded the FAA advisory but took no corrective action, stating it was “not mandatory.”
No fuel contamination, weather issues, or air traffic factors were found.
Both pilots were certified, rested, and fit for duty.
The black box showed that takeoff thrust was still engaged, while physical throttles were later found at idle — indicating a potential control disconnect.
The FAA bulletin was meant as a precaution, but the fatal consequence now puts global scrutiny on voluntary compliance in aviation safety.
Boeing, the FAA, and Honeywell are assisting Indian investigators, sources said.
A full safety audit of India’s 787 fleet has been ordered, they added.
The AAIB’s final report is expected to influence global oversight on equipment flagged in non-binding advisories — especially when they can be linked to fatal outcomes.