Air India’s Emergency 787 Checks: Is the Dreamliner Still Safe?

Air India has officially launched a high-stakes, fleet-wide inspection of the fuel control switches across its 33 Boeing 787 Dreamliners today, following a chilling report from the cockpit of flight AI 132. Less than 24 hours ago, a pilot on the London-Bengaluru route discovered that the left fuel control switch on aircraft VT-ANX failed to lock in the "RUN" position—a mechanical glitch that mirrors the suspected cause of the catastrophic June 2025 Ahmedabad crash.

The grounding of VT-ANX and the subsequent emergency engineering directive from SVP of Flight Operations Manish Uppal have sent shockwaves through the aviation industry. While the airline maintains these checks are "precautionary," the recurrence of a defect that was supposedly "cleared" in July 2025 has ignited a fierce debate over Boeing's hardware integrity and the transparency of previous safety audits.

The Context (How We Got Here)

• The Trigger: On Feb 2, 2026, the crew of VT-ANX reported the switch slipping toward the "CUTOFF" position during engine start at Heathrow, forcing an immediate grounding upon landing in Bengaluru.
• The Background: The June 12, 2025, Ahmedabad crash (260 fatalities) was linked by preliminary AAIB reports to fuel switches transitioning to "CUTOFF" during takeoff; Air India's July 2025 fleet-wide check had found no issues.
• The Escalation: Today’s move marks the second time in six months that Air India has been forced to inspect the Honeywell 4TL837-3D switch assembly, escalating the matter to Boeing for a "priority evaluation" of potential latch degradation.

The Key Players (Who & So What)

Manish Uppal (SVP Flight Operations, Air India): The Enforcer. His internal email to pilots ordering "prompt reporting" and fleet-wide re-inspections confirms the airline is no longer waiting for Boeing’s final verdict before taking action.

Capt. Amit Singh (Safety Matters Foundation): The Critic. He has publicly questioned the validity of the July 2025 "all clear" report, suggesting that either the previous inspections were superficial or the part itself suffers from a systemic design flaw.

Capt. CS Randhawa (President, Federation of Indian Pilots): The Hawk. Citing this as the "third known incident" (including a 2019 ANA flight in Osaka), he is calling for a total grounding of the 787 fleet until electrical or mechanical faults are definitively ruled out.

The BIGSTORY Reframe (The "Handling" Deflection)

While the media focuses on "Part Failure," a subtle game of blame-shifting is already underway. Preliminary DGCA leaks suggest the switch malfunction on VT-ANX might be due to "incorrect handling" or "angular force" by the pilot rather than a mechanical defect.

This is the Supply Chain Shield at work. By framing the issue as "Pilot Error," Boeing and Air India can avoid a massive, mandatory recall of the 4TL837-3D part. However, the "Silence of the Switch"—the fact that it can even be moved by "incorrect handling" without being lifted—points to a deeper mechanical vulnerability that the "abundance of caution" narrative is trying to mask.

The Implications (Why This Matters)

• Operational Gridlock: With 33 Dreamliners undergoing checks, passengers on long-haul routes (Delhi-London, Mumbai-Sydney) should expect rolling delays as engineering teams clear each aircraft.
• The 20,000-Hour Question: The failed switch on VT-ANX had logged only 3,500 hours, despite having a supposed service life of 20,000 hours. This discrepancy points to premature "Latch Fatigue."
• The Insurance Trap: If this is proven to be a design flaw, Air India could face massive litigation risks from the 2025 crash victims' families, who argue the airline ignored the 2018 FAA advisory on these very switches.

The Closing Question (Now, Think About This)

If a critical engine control can be compromised by "incorrect handling," is the failure with the pilot, or with the machine that allows such a fatal error to happen?

FAQs

Why is Air India inspecting its Boeing 787 fleet again? Because a pilot reported a fuel control switch malfunctioning on a London-Bengaluru flight (Feb 2, 2026), reviving fears related to the fatal 2025 Ahmedabad crash.

Is it safe to fly on an Air India Dreamliner right now? Air India has cleared 50% of its fleet as of Feb 3; only one aircraft (VT-ANX) is currently grounded. Inspections are ongoing for the remaining jets.

What is the issue with the Boeing 787 fuel switch? The switch (Part 4TL837-3D) is reportedly failing to stay locked in the "RUN" position, potentially slipping to "CUTOFF" and shutting down the engine inadvertently.

Did the DGCA ground the Air India 787 fleet? No. The DGCA has not issued a total grounding order; the fleet-wide inspection is a "precautionary" move initiated by Air India itself.

What part is causing the problem in the Air India Dreamliner? The focus is on the Fuel Control Switch (FCS) latch assembly, manufactured by Honeywell, which regulates fuel flow to the engines.

Sources

News Coverage

• The Hindu: Air India starts inspection of fuel control switches in its Boeing 787 planes
• ANI News: Air India begins inspection of fuel control switches, no glitches found so far

Context & Analysis

• Hindustan Times: Air India inspecting fuel switches: What’s the connection to the Ahmedabad crash?
• Channel News Asia: Air India inspects Boeing 787 fuel switches after grounding London flight