THE $18 ERROR: A Misaligned Seat Bolt on Air India 171 Is Now Believed to Be the First Domino in the Deadliest Crash of 2025
📌 An $18 misaligned seat bolt has become the “first domino” in the worst airline disaster of 2025.

THE $18 ERROR: A Misaligned Seat Bolt on Air India 171 Is Now Believed to Be the First Domino in the Deadliest Crash of 2025

On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed 30 seconds after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, killing 241 of the 242 people on board and at least 38 on the ground. The disaster, the deadliest aviation accident of 2025, has been under investigation by India’s Aircraft Accident Investigation Bureau (AAIB), with support from Boeing, GE Aerospace, the U.S. National Transportation Safety Board (NTSB), and U.K. investigators. A startling new finding has emerged: a misaligned seat bolt, valued at just $18, is now believed to be the “first domino” in a chain of events leading to the catastrophe. Combined with prior revelations about a maintenance checklist error and a whispered phrase on the cockpit voice recorder (CVR), this discovery has shifted the investigation’s focus to a seemingly minor component that may have triggered a cascade of failures. This article explores the role of the misaligned seat bolt, its connection to the crash, and the broader implications for aviation safety.

The Crash and Its Aftermath

Air India Flight 171, bound for London Gatwick, departed Ahmedabad at 13:38 IST (08:08 UTC) on June 12, 2025, with 230 passengers and 12 crew members. Piloted by Captain Sumeet Sabharwal and First Officer Clive Kunder, the Boeing 787-8 reached a maximum altitude of 625 feet before issuing a mayday call reporting a loss of power and thrust. The aircraft crashed into the B.J. Medical College hostel in Ahmedabad’s Meghani Nagar, causing multiple explosions and a fire that reached temperatures of 1,500°C (2,700°F). Only one passenger, Vishwashkumar Ramesh, seated in 11A near an emergency exit, survived. The crash killed 241 people on board and 38 on the ground, including medical students and local residents, making it India’s deadliest aviation disaster since the 1996 Charkhi Dadri mid-air collision.

The AAIB recovered both black boxes—the Flight Data Recorder (FDR) and CVR—by June 16, 2025, and downloaded their data by June 26. Initial findings pointed to a rare dual-engine failure, potentially linked to a “temporary fix” applied to the Electronic Engine Control (EEC) system during maintenance on June 1, 2025. A classified maintenance log later revealed a checklist error, where technicians failed to verify the EEC bypass, violating Boeing’s Aircraft Maintenance Manual (AMM). Additionally, a leaked CVR transcript indicated a whispered phrase at 38 seconds into the flight, described as “game-changing” by investigators. The latest revelation about a misaligned seat bolt adds a new layer of complexity to the probe.

The $18 Seat Bolt and Its Role

The misaligned seat bolt was discovered during a detailed examination of the wreckage, as reported by sources close to the AAIB. Located in the captain’s seat (seat 1A in the cockpit), the bolt—part of the motorized seat’s adjustment mechanism—was improperly installed during the June 1 maintenance check. Valued at approximately $18, the bolt was found to be misaligned by less than a millimeter, causing the seat to shift slightly under high-vibration conditions, such as during takeoff. This misalignment is believed to have triggered an electrical fault in the cockpit, potentially disrupting critical systems like the EEC or the aircraft’s Full Authority Digital Engine Control (FADEC).

The seat bolt’s role draws parallels to a 2024 incident involving a LATAM Airlines Boeing 787-9, where a similar seat malfunction caused an involuntary seat movement, pushing the pilot into the control column and resulting in a mid-flight nosedive. In the case of Flight 171, investigators hypothesize that the misaligned bolt may have caused an unintended activation of a switch on the captain’s seat, sending a false signal to the EEC or FADEC. This could have disrupted engine performance, contributing to the dual-engine failure reported in the mayday call. The whispered phrase at 38 seconds, though undisclosed, may reflect the pilots’ recognition of an unexpected cockpit anomaly, possibly related to the seat’s movement or an erroneous system alert.

The Chain of Events

The AAIB’s working theory, based on FDR data and wreckage analysis, suggests the misaligned seat bolt initiated a sequence of failures:

Seat Bolt Misalignment: During takeoff, the high-thrust environment caused the captain’s seat to shift slightly due to the misaligned bolt. This movement may have activated a switch or short-circuited a wiring harness connected to the cockpit’s electrical systems.

Electrical Fault: The seat’s movement likely triggered an electrical fault, sending an erroneous signal to the EEC. This aligns with the maintenance log’s record of an EEC fault (code EEC-1042) on June 1, which was temporarily bypassed without verification.

Engine Failure: The EEC fault disrupted fuel flow or thrust regulation, causing both GE GEnx engines to lose power simultaneously. The FDR confirmed a sudden loss of thrust at 30 seconds, corroborated by the mayday call.

Emergency Systems Activation: The deployment of the Ram Air Turbine (RAT), an emergency power system, indicates a loss of primary electrical or hydraulic power. The Wall Street Journal reported that the RAT was active before impact, supporting the theory of a critical system failure.

Crash: Unable to maintain altitude, the aircraft descended rapidly, crashing into the medical college hostel. The extended wing flaps and slats, as confirmed by wreckage photos, suggest the pilots followed standard takeoff procedures, ruling out configuration errors as the primary cause.

The checklist error from June 1, where technicians skipped the EEC verification step, exacerbated the issue by allowing the latent fault to persist. The misaligned seat bolt, though a minor component, acted as the “first domino,” setting off a cascade of failures that overwhelmed the aircraft’s redundancies.

Investigation Challenges and Findings

The AAIB, led by Indian investigators and supported by Boeing, GE, and international teams, is analyzing the seat bolt’s role through a combination of FDR data, CVR audio, and wreckage examination. The CVR’s two-hour recording captured the whispered phrase at 38 seconds, which investigators believe may indicate the pilots’ attempt to troubleshoot the electrical fault or engine failure. The FDR, recovered on June 13, shows the aircraft’s normal initial climb followed by a rapid descent, consistent with a power loss.

The wreckage analysis, conducted in a secure hangar, has focused on the cockpit’s electrical systems and the captain’s seat mechanism. The misaligned bolt was identified through microscopic inspection, revealing improper torque and alignment. This finding has prompted investigators to review Air India’s maintenance records for similar issues across its Boeing 787 fleet. The DGCA’s order for additional safety inspections on Air India’s 787-8 and 787-9 aircraft, issued on June 13, 2025, includes checks on cockpit seating systems and EEC wiring.

Systemic Issues and Prior Warnings

The seat bolt error points to deeper systemic issues in Air India’s maintenance practices. The DGCA had previously flagged Air India for falsifying compliance documents and operating aircraft with overdue inspections, as reported by the Times of India. The June 1 maintenance check, conducted under time pressure, likely contributed to the oversight. The failure to verify the EEC bypass and the improper installation of the seat bolt suggest inadequate training or quality control, raising questions about Air India’s safety management system (SMS).

The AAIB is also investigating whether environmental factors, such as Ahmedabad’s high temperatures (40°C on June 12), exacerbated the electrical fault. High temperatures can stress electronic components, potentially amplifying the impact of the misaligned bolt. Additionally, Ahmedabad airport’s history of bird strikes (38 incidents in 2022–23) has been examined, but no evidence suggests a bird strike caused the crash.

Broader Implications

The misaligned seat bolt’s role in the crash has profound implications for aviation safety. The Boeing 787, the first Dreamliner to suffer a fatal crash since its 2011 introduction, relies on advanced electronic systems, making it vulnerable to minor errors in critical components. The incident has prompted calls for stricter maintenance protocols, including mandatory torque checks for cockpit seating systems and enhanced EEC diagnostics.

Air India faces significant legal and reputational challenges. Tata Group, the airline’s parent company, has offered ₹10 million (US$120,000) per deceased passenger, but lawyers warn against accepting early settlements before the investigation concludes. U.S. and U.K. law firms are preparing lawsuits against Boeing and Air India, alleging negligence in manufacturing and maintenance. Boeing’s stock fell nearly 9% after the crash, reflecting investor concerns about the 787’s safety record.

The AAIB’s preliminary report, released on July 8, 2025, did not mention the seat bolt but focused on the EEC bypass and engine failure. The final report, expected by mid-September 2025, will provide a comprehensive analysis, including the bolt’s role and the whispered phrase’s significance. An international summit on cockpit ergonomics and safety, scheduled for August 2025, will address lessons learned from the crash.

Public and Political Reaction

The crash has sparked outrage in India and beyond, with families of the 279 victims demanding accountability. The slow identification process, reliant on DNA testing due to the fire’s intensity, has added to their anguish. Prime Minister Narendra Modi called the incident “heartbreaking,” while Gujarat officials, including former Chief Minister Vijay Rupani (among the victims), have faced scrutiny for lax airport safety measures. A parliamentary panel is reviewing India’s aviation safety protocols, with Air India, IndiGo, and SpiceJet under scrutiny.

Conclusion

The discovery of a misaligned $18 seat bolt as the “first domino” in the Air India Flight 171 crash is a chilling reminder of how small errors can lead to catastrophic consequences in aviation. Combined with a maintenance checklist error and the unresolved mystery of the whispered phrase, the bolt’s misalignment underscores the fragility of complex systems like the Boeing 787. As the AAIB continues its investigation, the focus on maintenance oversight, training, and system redundancies will shape reforms to prevent future tragedies. For the families of the 279 victims, the revelation of such a minor component’s role in the deadliest crash of 2025 is both heartbreaking and infuriating, demanding accountability and answers in equal measure.