Air India replaced crashed AI171 Dreamliner's fuel switch module twice since 2019

Air India replaced the Throttle Control Module (TCM)—a cockpit component that houses the fuel control switches—twice on the Boeing 787-8 Dreamliner (VT-ANB) that crashed in Ahmedabad on June 12, killing all 241 onboard and 19 people on the ground. The replacements were done in 2019 and 2023, in line with Boeing’s Maintenance Planning Document (MPD) which mandates a change every 24,000 flight hours.

The Aircraft Accident Investigation Bureau (AAIB), in its preliminary report, confirmed that the TCM changes were part of scheduled maintenance and not linked to any defect. The report stated that “as per the information from Air India, the suggested inspections were not carried out as the SAIB (Special Airworthiness Information Bulletin) was advisory and not mandatory.”

Cockpit voice recordings revealed that both engines lost power seconds after takeoff when the fuel switches were moved to "CUTOFF." One pilot was heard asking, “Why did you cut off the fuel?” to which the other replied, “I did not do so.” The engines briefly restarted when the switches were returned to “RUN,” but failed again before the aircraft could gain altitude.

The U.S. Federal Aviation Administration (FAA) issued a Continued Airworthiness Notification on July 11, stating the design of the fuel control switches does not pose an unsafe condition. Boeing also informed global 787 operators that no immediate action was required, citing the same findings. The AAIB referenced a 2018 FAA bulletin recommending checks on the locking mechanism of the switches, but noted it was not a mandatory directive.

Air India said it continues to cooperate with the investigation. Boeing confirmed it is supporting the inquiry as per ICAO Annex 13 protocols. The AAIB has not issued any interim recommendations for 787 or GE GEnx-1B engine operators. The full report into the cause of the crash is still under preparation.