Air India Crash Mystery: Fuel Switch Replaced Twice, Yet Jet Went Down

What began as a routine international flight turned into one of India’s deadliest aviation tragedies in recent history. The crash of Air India Flight AI171, a Boeing 787-8 Dreamliner, just minutes after takeoff from Ahmedabad on June 12, has shocked the nation—and the world.

As investigators dig deeper into the causes behind the fatal crash, a critical detail has now come to light: Air India had replaced the aircraft’s throttle control module (TCM) twice in the past six years. Despite this, both Boeing and U.S. aviation regulators maintain there is no immediate safety concern with the aircraft model.

Here’s what we know so far from the Aircraft Accident Investigation Bureau’s (AAIB) preliminary report.

Fuel Switches Cut Off Just After Takeoff

According to the AAIB report, both engines of the ill-fated Dreamliner shut down just seconds after takeoff when the fuel control switches were mysteriously set to ‘CUTOFF’ mode. This unexpected action led to a sudden loss of engine thrust, causing the aircraft to crash into a building near the airport, killing all 260 people onboard.

Cockpit Voice Recorder Reveals Shocking Exchange

Data recovered from the cockpit voice recorder revealed a chilling conversation between the two pilots. Seconds after the switches were cut: “Why did you cut off the fuel?” one pilot asked. “I did not do so,” the other responded.

Despite efforts to move the switches back to “RUN”, the engines only momentarily recovered before failing again. The aircraft couldn’t gain enough altitude and crashed within minutes.

TCM Replaced Twice, But Issue Remains Unresolved

Sources have confirmed that Air India replaced the Throttle Control Module (TCM)—a system that includes the fuel control switches—twice, once in 2019 and again in 2023, following a service directive from Boeing. However, neither replacement was linked to fuel switch defects, and no issues with the switches were reported after the last replacement.

Still, the exact cause of the switches transitioning to ‘CUTOFF’ mode is under investigation.

FAA and Boeing Respond: No Immediate Safety Risk

The Federal Aviation Administration (FAA) has issued a communication to international regulators acknowledging the AAIB’s findings but stated there are no urgent safety concerns with either the engines or systems of the Boeing 787-8.

Back in 2018, the FAA had issued a Special Airworthiness Information Bulletin (SAIB) warning that some fuel switches may be installed without their locking mechanisms engaged. But the SAIB was advisory, not mandatory, and Air India did not perform the suggested inspections since they were not required under the directive.

Boeing echoed FAA’s position, reiterating that the 787 remains safe to operate, and that the locking switch design is similar across other Boeing models.

What’s Next?

The full accident investigation is still ongoing, and a final report is expected in the coming months. Investigators are now focusing on whether a mechanical failure, design flaw, or human error led to the activation of the fuel cutoff mode.

Until then, questions remain—and so does the grief of a nation still mourning the loss of 260 lives aboard a plane that was supposed to safely fly from Ahmedabad to London.

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