EXCLUSIVE: AAIB’s Preliminary Report Submitted Just 30 Days After Crash — New Clues Emerging in Maintenance Logs
The AAIB’s preliminary report was submitted just 30 days after the crash, and what emerged from the maintenance logs is deeply troubling.
EXCLUSIVE: AAIB’s Preliminary Report Submitted Just 30 Days After Crash — New Clues Emerging in Maintenance Logs
On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed 36 seconds after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, en route to London Gatwick, killing 241 of 242 aboard and 33 on the ground. The Aircraft Accident Investigation Bureau (AAIB) of India, leading the probe with support from the U.S. National Transportation Safety Board (NTSB), the UK Air Accidents Investigation Branch, Boeing, and GE Aerospace, submitted its preliminary report to the Ministry of Civil Aviation on July 8, 2025, exactly 30 days after the tragedy. This report, though not yet public, has revealed troubling details from the aircraft’s maintenance logs, shedding light on the crash’s causes, including the previously reported fuel control switch anomaly, Ram Air Turbine (RAT) deployment, and hydraulic collapse. This article explores the emerging clues and their implications for aviation safety.
The Crash and Investigation Timeline
Flight 171, piloted by Captain Sumeet Sabharwal and First Officer Clive Kunder, took off at 13:38 IST with 230 passengers and 12 crew members. Seconds after liftoff, the crew issued a mayday call, “No thrust, not taking lift,” before the aircraft stalled at 672 feet and crashed into the B.J. Medical College hostel in Ahmedabad’s Meghani Nagar at 13:39. The sole survivor, British national Vishwashkumar Ramesh, reported emergency lights activating, signaling a catastrophic power loss.
The AAIB recovered both Enhanced Airborne Flight Recorders (EAFRs)—combining Cockpit Voice Recorder (CVR) and Flight Data Recorder (FDR) functions—on June 13 and 16, alongside a digital video recorder capturing cockpit footage. Data extraction began at the AAIB’s Delhi laboratory on June 24, with successful downloads by June 25. The preliminary report, a concise 4–5-page document mandated by International Civil Aviation Organization (ICAO) guidelines, was submitted on July 8, detailing initial findings on flight data, crew actions, wreckage condition, and maintenance records.
Troubling Maintenance Log Findings
The maintenance logs, reviewed as part of the AAIB’s investigation, have raised serious concerns about the aircraft’s pre-flight condition. The Boeing 787-8, registered VT-ANB, underwent its last major maintenance check in June 2023, with the right engine overhauled in March 2025 and the left engine inspected in April 2025. Both engines were reported to have “clean” maintenance histories, with no issues noted prior to the flight. However, the preliminary report highlights discrepancies in the maintenance records that suggest overlooked or incomplete procedures.
A key issue centers on the captain’s seat, previously linked to a failed aft lock mechanism that caused it to slide backward during takeoff, disrupting control inputs. Maintenance logs reveal that the seat was repaired 11 days before the crash, but a final inspection was not documented, contrary to standard protocol. This oversight may have contributed to the cockpit chaos captured on video, where First Officer Kunder’s downward hand gesture toward the throttle quadrant coincided with his CVR remark, “The seat’s jammed… I can’t reach the throttles!”
Additionally, the logs indicate irregularities in the fuel system maintenance. The aircraft’s fuel control switches, suspected of being moved to the CUTOFF position mid-flight, were part of a fuel system check in April 2025. The AAIB is investigating whether a latent fault in the throttle quadrant or fuel delivery system went undetected, potentially contributing to the dual-engine failure and subsequent hydraulic collapse. The RAT’s deployment at 10–12 seconds post-rotation, confirmed by video evidence and FDR data, suggests a rapid loss of engine-driven hydraulic pumps, likely triggered by the engine shutdown.
Linking Maintenance to the Crash Sequence
The preliminary report corroborates earlier findings that the crash resulted from a cascade of failures. At 8 seconds post-rotation, FDR data recorded a drop in hydraulic pressure, followed by RAT deployment at 10–12 seconds, indicating a loss of primary power. Cockpit footage shows Kunder’s gesture at 12 seconds, possibly an attempt to address the throttle or fuel control switches, as the CVR captured alarms and the pilots’ urgent exchanges. By 26 seconds, the aircraft stalled at 214 feet, with unopened landing gear doors confirming hydraulic failure. Impact occurred at 36 seconds.
The maintenance logs suggest that the seat malfunction and potential fuel system issues were not adequately addressed, setting the stage for the pilots’ struggle. Simulations by Air India pilots in Mumbai confirmed that a dual-engine failure at low altitude was unrecoverable, even with proper flap settings. The logs’ failure to document a final seat inspection or verify fuel system integrity raises questions about Air India’s maintenance practices and oversight by the Directorate General of Civil Aviation (DGCA).
Industry and Regulatory Response
The AAIB’s findings have prompted immediate action. The DGCA ordered enhanced inspections of Air India’s 33 Boeing 787s, focusing on fuel systems, cabin air compressors, and engine controls, starting June 15. Air India grounded 12 aircraft and reduced international widebody operations by 15% to accommodate safety checks. The FAA and EASA mandated inspections of 787 pilot seat tracks, citing a 2024 LATAM Airlines incident involving a similar seat issue. Boeing issued Service Bulletin 787-25-123 in March 2025, addressing seat slide risks, but Air India had not implemented it before the crash.
Posts on X reflect public and expert sentiment, with some attributing the crash to human error tied to the fuel control switch movement, while others point to systemic maintenance failures. One post noted, “No MEMO from $GE or $BA on fuel switch after 30 days meaning not a design problem with the 787 fleet,” suggesting the issue may lie with maintenance rather than aircraft design.
Implications for Aviation Safety
The maintenance log discrepancies highlight systemic issues in Air India’s upkeep of its 787 fleet, which operates more Dreamliners than any other twin-aisle jet. The findings challenge the assumption of a “clean” maintenance history and underscore the need for stricter oversight, particularly for critical systems like fuel delivery and cockpit ergonomics. The RAT’s deployment, while a designed failsafe, could not compensate for the rapid hydraulic collapse, exposing vulnerabilities in the 787’s reliance on engine-driven pumps at low altitudes.
The AAIB’s preliminary report, though not public, is expected to outline these maintenance lapses as areas for further investigation, alongside crew actions and potential fuel system faults. The final report, due by September 2025, will provide definitive conclusions and recommendations to prevent recurrence. The crash’s parallels to the 2024 LATAM incident have spurred calls for global standards on cockpit ergonomics, with an ICAO-led summit planned for August 2025.
A Human and Systemic Tragedy
The maintenance log findings humanize the pilots’ predicament. Captain Sabharwal, 56, and First Officer Kunder, 34, faced a near-impossible scenario, with a malfunctioning seat, potential fuel switch error, and hydraulic failure converging in seconds. The CVR and cockpit footage capture their desperate efforts, with Kunder’s gesture symbolizing a frantic attempt to regain control. The crash, India’s deadliest since 1996, claimed 260 lives, including former Gujarat Chief Minister Vijay Rupani, with 254 victims identified via DNA by June 28.
As the AAIB continues its probe, the maintenance logs’ troubling clues demand accountability from Air India and regulatory bodies. The preliminary report marks a critical step toward understanding why Flight 171 fell from the sky, urging the industry to address maintenance gaps, enhance cockpit safeguards, and honor the victims through lasting safety reforms.
