DGCA Issues Deadline for Boeing Fuel Switch Lock Inspection
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India’s aviation watchdog, the Directorate General of Civil Aviation (DGCA), has issued a strict directive to all Indian airlines operating select Boeing aircraft, asking them to inspect the fuel control switch locking mechanism by July 21, 2025. The move comes in response to global concerns raised after a recent Air India Boeing 787 Dreamliner crash, which has drawn attention to a potentially critical safety flaw.
Global Scrutiny Triggered by Air India Incident
The directive follows preliminary findings from the Aircraft Accident Investigation Bureau (AAIB) investigating the June crash of an Air India Dreamliner. According to the report, the aircraft lost thrust and crashed after both engines shut down shortly after takeoff-an incident traced back to the fuel control switches being moved to the “cutoff” position.
Investigators are still determining whether the switches were accidentally engaged by the pilots or failed mechanically. This incident has cast a global spotlight on the locking mechanism designed to prevent such unintended switch movements.
Although Boeing and US aviation regulators have maintained that the current design is safe, several international carriers-including Etihad Airways and Singapore Airlines-have already initiated internal checks. Now, India has made the inspection process mandatory, expanding the scope of concern.
DGCA Issues Nationwide Directive for Boeing Jets
In India, the DGCA has directed airlines to immediately inspect Boeing 787 aircraft and selected 737 variants-models that are widely operated by major carriers such as Air India, IndiGo, and SpiceJet.
Airlines have been instructed to submit their inspection schedules without delay and to complete all required checks by July 21. Final compliance reports must also be submitted to the aviation authority upon completion.
“The timeline must be strictly followed to ensure continued airworthiness and the safety of passengers and crew,” the DGCA emphasized in its advisory.
FAA Advisory from 2018 Resurfaces
Interestingly, this issue traces back to a 2018 bulletin issued by the US Federal Aviation Administration (FAA). The advisory flagged the potential for disengagement in the locking feature of fuel control switches across multiple Boeing aircraft series-including the 717, 737, 747, 757, 767, 787, and older MD-11 and MD-90-30 models.
Despite this, the advisory was not mandatory, and Air India reportedly did not implement any corrective measures, believing the issue did not apply to its 787 fleet. The airline told investigators that the aircraft in question had its throttle control module-which houses the fuel switches-replaced twice, once in 2019 and again in 2023, as per Boeing’s maintenance schedule.
Are Built-In Safeguards Enough?
Modern aircraft like the Boeing 787 are equipped with metal guards and locking mechanisms around the fuel switches, specifically designed to prevent accidental movement. These were introduced following earlier incidents on older Boeing models.
However, the recent Air India crash has raised serious questions about whether these safety features are enough. Did the locking mechanism fail? Was it bypassed or misused during operation? These are some of the key questions investigators are now trying to answer.
Air India flight AI 171, a Boeing 787-8 bound for London Gatwick, crashed shortly after takeoff from Ahmedabad on June 12, resulting in the tragic loss of all 260 lives on board.
Airlines on High Alert
The global aviation community is taking note. While some carriers have begun voluntary inspections, India’s directive marks one of the strongest regulatory actions in the wake of the Dreamliner incident.
With July 21 looming, Indian carriers are now racing against the clock to complete inspections, ensure compliance, and reassure passengers of their commitment to safety.
Global Scrutiny Triggered by Air India Incident
The directive follows preliminary findings from the Aircraft Accident Investigation Bureau (AAIB) investigating the June crash of an Air India Dreamliner. According to the report, the aircraft lost thrust and crashed after both engines shut down shortly after takeoff-an incident traced back to the fuel control switches being moved to the “cutoff” position. Investigators are still determining whether the switches were accidentally engaged by the pilots or failed mechanically. This incident has cast a global spotlight on the locking mechanism designed to prevent such unintended switch movements.
Although Boeing and US aviation regulators have maintained that the current design is safe, several international carriers-including Etihad Airways and Singapore Airlines-have already initiated internal checks. Now, India has made the inspection process mandatory, expanding the scope of concern.
DGCA Issues Nationwide Directive for Boeing Jets
In India, the DGCA has directed airlines to immediately inspect Boeing 787 aircraft and selected 737 variants-models that are widely operated by major carriers such as Air India, IndiGo, and SpiceJet. Airlines have been instructed to submit their inspection schedules without delay and to complete all required checks by July 21. Final compliance reports must also be submitted to the aviation authority upon completion.
“The timeline must be strictly followed to ensure continued airworthiness and the safety of passengers and crew,” the DGCA emphasized in its advisory.
FAA Advisory from 2018 Resurfaces
Interestingly, this issue traces back to a 2018 bulletin issued by the US Federal Aviation Administration (FAA). The advisory flagged the potential for disengagement in the locking feature of fuel control switches across multiple Boeing aircraft series-including the 717, 737, 747, 757, 767, 787, and older MD-11 and MD-90-30 models. Despite this, the advisory was not mandatory, and Air India reportedly did not implement any corrective measures, believing the issue did not apply to its 787 fleet. The airline told investigators that the aircraft in question had its throttle control module-which houses the fuel switches-replaced twice, once in 2019 and again in 2023, as per Boeing’s maintenance schedule.
Are Built-In Safeguards Enough?
Modern aircraft like the Boeing 787 are equipped with metal guards and locking mechanisms around the fuel switches, specifically designed to prevent accidental movement. These were introduced following earlier incidents on older Boeing models. However, the recent Air India crash has raised serious questions about whether these safety features are enough. Did the locking mechanism fail? Was it bypassed or misused during operation? These are some of the key questions investigators are now trying to answer.
Air India Flight Crash
Air India flight AI 171, a Boeing 787-8 bound for London Gatwick, crashed shortly after takeoff from Ahmedabad on June 12, resulting in the tragic loss of all 260 lives on board.
Airlines on High Alert
The global aviation community is taking note. While some carriers have begun voluntary inspections, India’s directive marks one of the strongest regulatory actions in the wake of the Dreamliner incident. With July 21 looming, Indian carriers are now racing against the clock to complete inspections, ensure compliance, and reassure passengers of their commitment to safety.
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