By Aviation Nexus
July 24–25, 2025 — The U.S. Federal Aviation Administration (FAA) has confirmed that no mechanical defect was found in the fuel control units of Boeing 787 Dreamliners involved in the tragic Air India Flight AI 171 crash. FAA Administrator Bryan Bedford stated that exhaustive testing and inspection ruled out mechanical or inadvertent failures of the fuel cutoff units that govern engine fuel flow .
Flight AI 171, a Boeing 787‑8 operating from Ahmedabad to London Gatwick on June 12, suffered an abrupt fuel cutoff to both engines moments after liftoff, prompting a catastrophic crash that claimed 241 lives onboard and 19 on the ground, marking the deadliest aviation disaster of the decade . Data from India’s Aircraft Accident Investigation Bureau (AAIB) indicates both engine fuel control switches moved from “RUN” to “CUTOFF” within a one‑second interval shortly after takeoff, leading to dual engine flameout .
FAA Advisory Context and Boeing Position
In December 2018, the FAA issued a Special Airworthiness Information Bulletin (SAIB) warning that the locking mechanism on fuel control switches installed on certain Boeing aircraft—including the 787—could disengage, allowing the switches to move accidentally, potentially causing an unintended engine shutdown .However, the FAA did not deem this risk sufficient to issue a mandatory Airworthiness Directive, describing it as an advisory matter subject to operator discretion
Boeing later circulated a Multi‑Operator Message reaffirming the FAA’s assessment that the design, including the locking feature, does not constitute an unsafe condition needing mandatory corrective action .
Indian Response and Fleet Inspections
Following the AAIB’s preliminary findings, India’s Directorate General of Civil Aviation (DGCA) directed all operators of Boeing 787 and selected 737 variants to inspect the fuel switch locking systems by July 21. Air India promptly conducted voluntary inspections across its 787 and 737 fleet, reporting no anomalies in the locking mechanisms .
Additionally, documentation reveals that the affected aircraft had its throttle control module—including the fuel control switches—replaced in 2019 and again in 2023 as part of routine Boeing‑recommended maintenance, though not specifically tied to the SAIB advisory issue
