FAA Declares Boeing Fuel Control Switches Safe After Deadly Air India Crash

Despite AAIB probe revealing possible switch issue in Dreamliner crash, U.S. regulator finds no grounds for urgent safety directive

The Federal Aviation Administration (FAA) of the United States has declared the fuel control switch design used in Boeing aircraft, including the Dreamliner, to be safe, following a preliminary investigation into the fatal crash of Air India Flight AI171 in Ahmedabad. The crash, which involved a Boeing 787-8 Dreamliner, resulted in the tragic deaths of over 275 people, including passengers, crew, and civilians on the ground.

In a formal notice dated July 11, the FAA communicated to civil aviation authorities worldwide that no airworthiness directive (AD) is currently necessary for Boeing operators. Airworthiness directives are mandatory actions issued to rectify potentially hazardous conditions in aircraft components or systems. However, in this case, the FAA stated that despite similarities in fuel switch designs across Boeing models, including the 737 and 787, no unsafe condition was found that warrants mandatory intervention.

This notification follows preliminary findings released by India’s Aircraft Accident Investigation Bureau (AAIB) regarding the AI171 crash. The report revealed that both engines of the aircraft shut down within seconds of take-off after the fuel control switches were moved from the “RUN” to the “CUT-OFF” position, resulting in a complete loss of engine thrust. Intriguingly, neither pilot acknowledged activating the switches, with the cockpit voice recorder capturing one pilot asking, “Why did you cut off?”, and the other responding, “I didn’t.”

Adding to the complexity of the case, the AAIB highlighted a 2018 FAA bulletin that warned of potential issues with Honeywell-manufactured fuel control switches used in several Boeing models. The bulletin recommended inspection of the locking mechanisms in these switches — particularly the ‘cut-off’ position, which had reportedly malfunctioned in the past when the locking feature was disengaged.

Despite this advisory, Air India did not conduct the suggested inspections, citing the bulletin’s non-mandatory nature. The airline informed investigators that since the directive was “advisory,” compliance was not obligatory. Maintenance records show that Air India had replaced the throttle control module twice, in 2019 and 2023, although these replacements were not related to the fuel switch system. No reported defects linked to the fuel switches have been recorded on the aircraft since 2023.

In response to growing concerns, the FAA emphasized that the locking feature design of the switches is consistent across Boeing aircraft, including the 787 Dreamliner, but found no systemic failure that would demand urgent remedial action.

A spokesperson for the FAA, when approached for further comment, simply stated that the administration had nothing to add beyond the contents of the official notice.

The crash investigation is being carried out in collaboration with the US National Transportation Safety Board (NTSB) and the UK’s Air Accidents Investigation Branch (AAIB), under protocols set by the International Civil Aviation Organization (ICAO). The FAA is providing technical support to the probe.

While the final cause of the crash has yet to be determined, some aviation experts have pointed to the possibility that a malfunction in the locking mechanism of the fuel control switches may have caused them to shift to the cut-off position unintentionally. If true, this could have resulted in the sudden and complete loss of fuel supply, ultimately leading to the catastrophic engine failure shortly after takeoff.

For now, the FAA’s stance offers some reassurance to airlines and passengers operating Boeing aircraft globally. But for the victims’ families and aviation authorities, questions remain unanswered as investigators dig deeper into the technical and human factors behind one of India’s deadliest aviation disasters in recent years.