The tragic Air India AI-171 crash has revealed deeply unsettling questions about maintenance practices, regulatory oversight, and airline accountability. In an exclusive report, CNN-News18 has accessed a 2018 warning by the Federal Aviation Administration (FAA), which had alerted Boeing 737 operators about a potential engine shutdown risk due to issues in the fuel control switch’s locking mechanism. This very issue, now being scrutinised by investigators, is suspected to have played a pivotal role in the engine failure that led to the fatal crash of VT-ANB, a Boeing 787-8 aircraft operated by Air India.

According to the preliminary report by the Aircraft Accident Investigation Bureau (AAIB), the FAA had received reports from various Boeing 737 aircraft operators that the fuel control switches were being installed with the locking feature disengaged. The fuel control switch, a critical component located on the control stand in the flight deck, allows the pilot to either supply or cut off fuel to the aircraft’s engines. The locking feature is designed to prevent accidental transition between these states. But if this feature is disengaged, the switch can be toggled freely—risking inadvertent engine shutdowns, especially during sensitive phases such as take-off.

The FAA directive explicitly warned, “Inadvertent operation of the switch could result in an unintended consequence, such as an in-flight engine shutdown.”

To ensure safety, the FAA had recommended that all owners and operators of affected Boeing aircraft check whether the fuel control switches required lifting before changing position. If the switch could be moved without lifting, it meant the locking mechanism was disengaged—posing a major operational hazard.

The advisory further recommended replacing older switches (Part No. 766AT613-3D) with an improved model (Part No. 766AT614-3D) which incorporated a more secure locking mechanism. While this advisory applied to specific Boeing 737 series aircraft, the design of the switch—including its vulnerabilities—was shared across several Boeing aircraft types, including the B787-8 model VT-ANB, which was involved in the AI-171 crash.

Air India’s Response and Oversight

Despite this clear warning, Air India did not take any action. The airline acknowledged to investigators that the FAA directive was advisory, not mandatory, and hence was not implemented.

The AAIB report confirms that the maintenance records for aircraft VT-ANB show throttle control module replacements in 2019 and 2023, but none were connected to the fuel control switch. Furthermore, no formal defect related to the fuel switch was reported between 2023 and the time of the 2025 crash.

This has raised serious concerns among aviation experts and regulatory bodies, questioning why such a critical recommendation regarding engine safety was ignored—especially for older aircraft in commercial operation.

What Happened on AI-171

As the Air India AI-171 flight accelerated past 180 knots during takeoff, Engine 1 and Engine 2 fuel cut-off switches transitioned from RUN to CUTOFF in rapid succession, only one second apart. The engines then began to shut down, their N1 and N2 parameters dropping, signalling a complete fuel supply cut.

The cockpit voice recorder revealed a chilling moment of confusion and disbelief: one pilot asked the other, “Why did you cut off?” to which the second pilot replied, “I didn’t.” Moments later, they attempted to restart the engines—but it was too late.

This sudden, synchronous switch transition has fueled speculation that the locking mechanism may have failed, or that the switches were accidentally triggered without pilot intent, a possibility that matches exactly with what the FAA warned about in 2018.

Systemic Oversight and Responsibility

Aviation safety experts have stressed that advisories, though not legally binding, often contain critical safety insights. Ignoring them can lead to disasters, particularly when they pertain to core mechanical components like engine switches. In this case, Air India’s decision to skip implementation, simply because the FAA notice wasn’t a mandatory directive, may have had fatal consequences.

In addition, the shared nature of Boeing’s fuel switch design across its models suggests that the hazard applied not just to older 737 aircraft, but also to modern Dreamliners like the B787-8. Investigators are now assessing whether similar switches with disengaged locking could be installed on other Air India aircraft, prompting calls for a fleet-wide safety audit.

Adding to the controversy are reports that MPs and aviation watchdogs are demanding an audit of the Aviation Security Bureau and a complete review of Air India’s maintenance protocols post-privatisation. They have questioned whether safety standards were diluted, and whether cost-saving measures came at the expense of critical component upgrades.

Could This Tragedy Have Been Prevented?

Many experts believe it could have. Had the 2018 FAA fuel switch advisory been taken seriously and applied across all aircraft with similar switch designs, the locking feature issue might have been addressed in advance. The advisory even specified that a simple ground inspection could determine if the locking feature was disengaged. If so, replacing the switch proactively could have prevented the tragic AI-171 engine shutdown.

The fact that both engine cut-off switches flipped within a second of each other strongly suggests accidental or systemic failure, not human error. With both pilots denying intentional cut-off, and with no prior technical complaints about the switch, the focus has now narrowed to the design flaw and operational oversight.

Moving Forward: Safety or Complacency?

The AI-171 disaster has reignited a crucial debate around aviation safety standards in India, particularly concerning legacy aircraft still in active commercial use. The episode has also highlighted the importance of treating advisories with urgency, especially when they address life-critical systems like engine controls.

The FAA, while not making the directive mandatory in 2018, issued it in response to multiple operator complaints. Boeing was expected to act on it—and so were the airlines. However, Air India’s reluctance to act on a non-binding notice and the absence of further follow-up or audit reflect a systemic complacency that now demands urgent correction.

As the investigation continues, pressure mounts on Air India to publicly address why the fuel switch inspection and part replacement were not prioritized. Families of the victims, aviation regulators, and industry observers alike are demanding transparency, accountability, and above all, assurance that such lapses will never happen again.

This tragedy stands as a grim reminder that in aviation, every advisory counts, and every component matters. Ignoring a warning—even a non-mandatory one—can cost lives.

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