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The 2018 FAA Warning That Went Unheeded: Could It Have Prevented the Air India Crash?

  • Knowledge Barrel
  • 7 hours ago
  • 3 min read

In the wake of the tragic Air India Flight AI171 crash in June 2025, investigators and aviation experts are digging deep into every possible factor that may have contributed to the disaster. One crucial piece of the puzzle is a 2018 FAA bulletin that flagged potential issues with the Boeing 787’s fuel-switch locking mechanism.


Though the bulletin raised concerns, no mandatory action was taken at the time. Today, that decision is under fresh scrutiny—especially since Flight AI171’s engines shut down midair, reportedly after the fuel switches were found in the 'CUTOFF' position, resulting in the deaths of 260 people.


So what exactly was in that FAA bulletin? Why was it overlooked? And could it have made a difference?


Understanding the FAA Bulletin


Back in 2018, the Federal Aviation Administration (FAA) issued a Special Airworthiness Information Bulletin (SAIB) to airlines and aircraft maintenance crews operating Boeing 787 Dreamliners. The bulletin highlighted a potential vulnerability in the fuel control switch lock mechanism, which could allow the switch to move unexpectedly under certain conditions.


The switch in question is a manual lever that controls whether fuel flows to the aircraft’s engines. It has two key positions:


  • RUN – Fuel flows normally to power the engine

  • CUTOFF – Fuel supply is stopped, shutting down the engine


To avoid accidental activation, the switch is designed with a locking or guarding mechanism. However, the FAA bulletin pointed out cases where the lock was not functioning correctly, or where the switch could potentially be moved with minimal resistance—especially during turbulence, maintenance, or under faulty installation.


No Mandatory Action Taken


Despite the seriousness of the issue, the FAA’s 2018 bulletin was advisory only. That means it was a recommendation, not a requirement. Unlike Airworthiness Directives (ADs), which compel airlines to conduct inspections, repairs, or modifications, SAIBs are informational. They aim to raise awareness, but do not require compliance.

As a result, many airlines—including possibly Air India—may have skipped or postponed inspections related to this fuel switch lock concern. It remains unclear whether Flight AI171 underwent any checks following the 2018 alert. This is what makes the situation so controversial.


The Connection to the 2025 Air India Crash


In the case of Flight AI171, both engine fuel control switches were moved to CUTOFF shortly after takeoff, causing the engines to lose power and the plane to crash into a residential area near Ahmedabad.


Initial findings from the investigation have not confirmed whether this was a mechanical failure or human error, but the timeline is shocking:


  • The left engine switch was moved to CUTOFF

  • One second later, the right engine switch followed

  • A cockpit voice recorder captured the pilot saying,

    “Why did you cut off the fuel?”“I did not do so.”


This exchange suggests confusion in the cockpit, and raises the possibility that neither pilot intentionally moved the switches. This has led investigators to re-examine the 2018 FAA bulletin, as the failure of the locking mechanism could potentially explain the switches moving on their own—or being moved more easily than intended.


Industry Reactions: A Wake-Up Call?


In the aftermath of the crash, aviation regulators around the world are re-evaluating the 2018 bulletin. Some key reactions include:


  • FAA officials have said they are reviewing whether a more forceful directive should have been issued at the time.

  • Aviation safety analysts argue that known mechanical vulnerabilities—especially involving critical systems like fuel control—should never be treated as optional fixes.

  • Families of victims have started calling for accountability, asking why a known safety concern was not acted on more aggressively.


If the investigation ultimately confirms that a faulty fuel switch lock contributed to the crash, the consequences for Boeing, Air India, and global regulators could be significant.


A Missed Opportunity for Prevention?


Hindsight is always clearer, but this incident may serve as a hard lesson in the importance of acting on even advisory-level warnings when safety is at stake.

The 2018 FAA bulletin was a red flag—one that could have prompted preemptive inspections, retrofits, or at least a more cautious approach by airlines. But in the absence of mandatory directives, safety improvements were left to individual discretion.

Now, with 260 lives lost, the aviation world is left wondering: Would a stronger response to that bulletin have saved Flight AI171?

Only time—and a full investigation—will tell.

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