FAA Warning Ignored: The Overlooked Threat Behind the Air India Crash

Families and aviation experts are demanding answers following the deadly crash of Air India Flight 171. A chilling detail emerged from the preliminary investigation: the FAA ignored a critical warning prior to the disaster.

Investigators are uncovering a previously overlooked threat as they piece together the events. The focus is now on a small but vital component: the fuel control switch locking mechanism and a safety bulletin that may have gone unheeded.

What was the FAA warning about fuel switch safety?

In 2018, the US Federal Aviation Administration issued Special Airworthiness Information Bulletin (SAIB) No. NM-18-33. This bulletin highlighted concerns about fuel control switch locking mechanisms on Boeing aircraft, including the 787 model flown by Air India.

The FAA cautioned that disengaging these locking features could easily move the fuel switches. This could happen due to vibration, accidental contact, or other unforeseen factors, potentially leading to catastrophic engine shutdowns during flight.

The bulletin recommended airlines inspect and confirm that all locking mechanisms were properly engaged. However, the FAA stopped short of making this a mandatory requirement, leaving it to airlines to decide whether to act.

Did you know?
The FAA issues hundreds of safety bulletins each year, but only a small fraction become mandatory directives. Many airlines worldwide treat non-mandatory advisories as optional, sometimes with fatal consequences.

Could a simple oversight have prevented the tragedy?

Air India, like many airlines, did not carry out the recommended inspections. The airline reasoned that since the FAA bulletin was advisory and not a formal airworthiness directive, there was no obligation to comply.

The Aircraft Accident Investigation Bureau (AAIB) report confirms that Air India had replaced the throttle control module on the crashed aircraft twice in recent years. However, the FAA's flagged fuel switch locking mechanism issue had nothing to do with these replacements.

This revelation raises a haunting question: could a simple, non-mandatory inspection have averted the loss of 260 lives? The preliminary report does not provide a definitive answer, but the possibility is now at the center of the investigation.

The FAA bulletin raised concerns about fuel switch locking mechanisms

The 2018 bulletin was issued after reports surfaced of Boeing 737 fuel control switches being installed with their locking features disengaged. Although there were no immediate accidents associated with this issue at the time, the FAA recognized sufficient risk to notify all operators of the affected aircraft.

Locking mechanisms are designed to prevent inadvertent movement of fuel switches. When disengaged, switches can be nudged or vibrated out of position, potentially cutting off fuel to the engines without the crew's intent.

In the case of Air India Flight 171, the AAIB report notes that both engine fuel cutoff switches moved from RUN to CUTOFF within one second of each other, just as the aircraft reached takeoff speed. The cause of this movement remains under investigation, but the role of the locking mechanism is a major focus.

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Ignored advisories highlight gaps in global airline safety

The tragedy has exposed a troubling gap in how airlines interpret safety advisories. While mandatory directives must be followed, advisories like the 2018 FAA bulletin are often treated as optional, even when they concern critical systems.

Aviation experts warn that this approach can leave dangerous vulnerabilities unaddressed. In the competitive world of commercial aviation, cost and compliance pressures sometimes override proactive safety measures, especially when official guidance is not enforced.

The Air India crash has prompted calls for stricter oversight and a re-examination of safety information communication and action worldwide. Families of the victims and aviation advocates are demanding that all advisories, especially those related to flight-critical systems, be treated with the utmost seriousness.

As the investigation continues, authorities are analyzing black box data, fuel samples, and mechanical components to determine the precise sequence of events. The final report is expected to take months, if not years, to complete.

This tragedy has reignited urgent debate about the balance between regulatory authority and airline autonomy. The world will be watching closely as investigators seek to ensure that such an overlooked threat never claims lives again.