The U.S. Federal Aviation Administration (FAA) and Boeing have reaffirmed the safety of fuel switch locks on Boeing aircraft amid an ongoing investigation into the tragic crash of Air India Flight 171, which occurred on June 12, 2025. The crash, which resulted in 261 fatalities including 19 people on the ground, happened moments after takeoff from Ahmedabad when both fuel control switches of the Boeing 787-8 aircraft inexplicably moved from "RUN" to "CUTOFF", cutting off engine power and leading to the catastrophic descent into a residential building.
Preliminary findings from India’s Aircraft Accident Investigation Bureau (AAIB) confirmed that the fuel switches were indeed toggled during the critical moment shortly after takeoff. Cockpit voice recordings revealed a moment of confusion between the two pilots, one of whom asked, “Why did you cut off the fuel?” to which the other responded, “I did not do so.” Investigators are yet to determine whether the switches were activated due to human error, mechanical failure, or another unidentified factor.
In response to growing global scrutiny, the FAA issued a Continued Airworthiness Notification on July 11 stating that the design of the fuel switch locks, which includes a guard and a lift-to-unlock mechanism, does not present an unsafe condition. The FAA concluded that there was no need for an Airworthiness Directive or any mandatory changes to the current design. Boeing echoed this conclusion through a message to all operators, stating that no immediate action was required.
Despite these assurances, the crash has sparked significant concern among aviation safety experts and the families of the victims. The fuel control switches in question had been replaced in 2019 and 2023 as part of routine maintenance based on service hours, and there were no recorded defects. However, critics have noted that Air India did not act on a 2018 FAA Special Airworthiness Information Bulletin that recommended optional inspections of the locking mechanism, potentially missing a chance to detect any emerging issues.
The AAIB’s initial report has faced criticism from victims' families and pilot unions for lacking detail and transparency. Calls have been made for further independent oversight of the investigation, with India's Air Line Pilots’ Association (ALPA) pushing for observer status to ensure fairness in the final reporting process.
While both the FAA and Boeing maintain that the fuel switch locks are safe and that no design flaw is currently evident, the question remains how both switches could have moved simultaneously to the “CUTOFF” position during flight. Analysts suggest that further insights may emerge from detailed analysis of the flight data recorder and other cockpit systems.
The full investigation report is expected to take several more months. Until then, the aviation industry continues to monitor developments closely, with potential implications for cockpit safety protocols and aircraft maintenance procedures worldwide.