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Tragedy Sparks Scrutiny Over Boeing’s Fuel Control Switches

The U.S. Federal Aviation Administration (FAA) has reaffirmed the safety of fuel control switches used in Boeing aircraft, despite their reported involvement in a devastating Air India crash that killed 260 people in June 2025.

The crash of Air India Flight 171, a Boeing 787-8 Dreamliner en route from Ahmedabad to London, has become one of the most fatal aviation disasters in nearly a decade. The preliminary investigation found that fuel to both engines was unexpectedly cut off shortly after take-off, causing the aircraft to lose thrust and crash. Among the 260 casualties were 229 passengers, 12 crew members, and 19 people on the ground. A single British passenger survived.

Preliminary Findings Raise Safety Questions

In its early report, India’s Aircraft Accident Investigation Branch (AAIB) stated that the fuel control switches had shifted from "run" to "cut-off" in the seconds following take-off — an action that directly shut down engine power.

Adding to the concerns, the report referenced a 2018 FAA advisory that encouraged operators to inspect the locking mechanisms of these switches. The advisory cited incidents where switches were found with locking features disengaged, potentially making them vulnerable to accidental movement. Importantly, the FAA did not mandate the inspection at that time.

The AAIB noted that Air India had not conducted these inspections, a detail that has drawn increased attention following the crash.

FAA Responds: “No Unsafe Condition Identified”

Following the release of the AAIB’s preliminary findings, the FAA issued an internal note to international aviation authorities. In it, the U.S. regulator acknowledged the historical concerns raised in 2018 but emphasized that the fuel switch design has not been found to pose an inherent safety risk.

“The FAA does not consider this issue to be an unsafe condition that would warrant an Airworthiness Directive on any Boeing airplane models, including the Model 787,” the note read.

It added that while the switch mechanism is similar across multiple Boeing aircraft, there has been no sufficient evidence to justify regulatory action at this point.

Cockpit Confusion Adds Complexity

The AAIB’s report also revealed that cockpit voice recordings captured one pilot asking the other why the fuel switches were turned off. The co-pilot responded that he had not done so, suggesting that both switches may have been inadvertently or mysteriously triggered.

At this stage, investigators have not determined how or why the switches were moved to the cut-off position. There was no mention of mechanical failure, system malfunction, or deliberate action.

Air India CEO Urges Caution on Early Conclusions

Air India CEO Campbell Wilson responded promptly to the findings, urging the public and media to avoid “premature conclusions.” In an internal memo to staff, Wilson emphasized that the investigation is ongoing and that the preliminary report does not assign cause or make any recommendations at this stage.

“There is an ongoing cycle of theories, allegations, rumours, and sensational headlines,” Wilson wrote. “Many of which have since been disproven. The investigation is far from over.”

He also confirmed that no mechanical or maintenance faults had been found in the aircraft or engines, and all required checks were performed before take-off.

Air India Takes Preventive Action Across Fleet

Out of caution, Air India conducted additional safety checks across its entire Boeing 787 fleet in the days following the crash. Wilson noted that all aircraft were cleared and deemed airworthy.

The airline also stated its full cooperation with authorities from India, the United States, and Boeing to aid in a comprehensive, transparent investigation.

A Closer Look at Boeing’s Fuel Switch Advisory History

Boeing and the FAA first raised flags about the fuel control switches in 2018, citing incidents where the locking mechanism — designed to prevent accidental deactivation — had been installed improperly or disengaged during maintenance.

However, the advisory only encouraged inspections and did not enforce compliance through an Airworthiness Directive, which is typically issued when a component poses a clear and immediate threat to flight safety.

Safety experts now say the 2018 advisory may come under renewed scrutiny, especially if future reports link switch mechanics directly to the Air India crash.

What's Next?

The AAIB has said that a final report will be issued in 12 months, incorporating flight data analysis, system simulations, crew interviews, and manufacturer input.

Until then, the aviation community continues to watch closely. With Boeing already under pressure from other regulatory issues in recent years, any further developments could have significant implications for the commercial aerospace sector, airline safety protocols, and manufacturer accountability going forward.