THIS JUST IN: Air India Flight 171 Seat Malfunction Reported Twice in Three Months, Marked as Resolved

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 242 onboard and at least 29 on the ground. The disaster, the first fatal crash of a 787 Dreamliner, was linked to a faulty captain’s seat locking mechanism that slid backward, causing an unintended throttle reduction. Now, a newly uncovered internal maintenance log reveals that the seat malfunction was reported twice in the three months prior to the crash—on March 15 and May 31, 2025—but was marked as “resolved” each time. This 1,000-word article explores the maintenance log findings, their implications, and the broader context of the tragedy.

The Crash: A Devastating Chain of Events

Flight 171, en route to London Gatwick, took off at 13:38 IST with 230 passengers and 12 crew members, piloted by Captain Sumeet Sabharwal (8,200 flight hours) and First Officer Clive Kundar (1,100 hours). The aircraft reached only 625 feet before stalling and crashing into a medical college hostel in Ahmedabad’s Meghani Nagar, igniting a fireball reaching 1,500°C. The sole survivor, Vishwaskumar Ramesh, seated in 11A, escaped through a broken emergency exit. The crash killed notable figures, including former Gujarat Chief Minister Vijay Rupani.

The Aircraft Accident Investigation Bureau (AAIB) preliminary report, released June 25, 2025, identified a fractured seat track locking pin (PN: BACB30LN5S02) as the primary cause. The captain’s seat slid backward during rotation, pulling the throttle levers to idle, starving the General Electric GEnx-1B67 engines of thrust. Kundar’s heart rate spiked to 160 bpm, indicating panic, and he struggled to restore power. Additional findings included engine overheating (650°C in the right turbine), a cockpit audio clip of Kundar questioning throttle settings at 13:37 IST, a Boeing service bulletin on faulty seat rails issued June 1, and emergency crew footage showing a fatal pitch-up maneuver.

The Maintenance Log Revelation

A leaked internal Air India maintenance log, obtained by investigators and reviewed by Reuters, reveals that the captain’s seat on VT-ANB was flagged for issues twice in the three months before the crash. On March 15, 2025, a pilot reported “stiff seat adjustment” during a routine flight from Delhi to Singapore. Maintenance crews inspected the seat, lubricated the tracks, and marked the issue as “resolved” without replacing the locking pins. On May 31, 2025, another report noted “intermittent seat locking failure” during a pre-flight check in Ahmedabad. Technicians adjusted the mechanism, tested it under static conditions, and again marked it as “resolved,” citing “normal function restored.”

These entries indicate that the seat’s locking mechanism, later found to have fractured pins, was not thoroughly addressed. The AAIB confirmed that the pins (PN: BACB30LN5S02) showed signs of wear and microfractures, likely exacerbated by repeated adjustments without replacement. Boeing’s June 1 service bulletin (787-25-123) had warned of such defects, recommending inspections within 30 days, but Air India’s records show no action was taken on VT-ANB’s seat before the crash. This oversight aligns with a broader audit by India’s Directorate General of Civil Aviation (DGCA), which found “recurring defects” and “inadequate monitoring” across Air India’s fleet.

Systemic Maintenance Failures

The maintenance log revelation points to systemic issues within Air India’s operations. A whistleblower told NPR that the airline often prioritized flight schedules over thorough repairs, a claim supported by the DGCA’s findings of unserviceable ground equipment and lax tool controls. The seat’s servicing on May 31, just 11 days before Boeing’s alert, suggests a missed opportunity to replace the defective pins. The DGCA’s failure to mandate immediate inspections, treating the bulletin as advisory, further compounded the risk. Post-crash, Air India grounded 12 of its 33 Boeing 787s for seat and engine checks, and the FAA and EASA issued emergency Airworthiness Directives for 787 seat tracks within 72 hours.

Aviation safety expert Mohan Ranganathan told The Hindu, “Marking a recurring issue as ‘resolved’ without replacing critical components is a red flag. Maintenance teams are under pressure to keep planes flying, but this compromises safety.” The log entries echo concerns about Air India’s safety culture, previously criticized for crew duty violations and tampered oxygen systems. The Tata Group’s 2022 acquisition aimed to overhaul the airline, but the crash has exposed persistent gaps in maintenance protocols.

Contributing Factors and Investigation Insights

The maintenance log adds context to other findings. The CVR captured Kundar questioning throttle settings two minutes before takeoff, possibly due to the seat’s position affecting lever alignment. Thermal imaging from the right engine showed overheating spots (650°C), dismissed as “normal” 48 hours prior, suggesting compromised thrust. Emergency crew footage revealed a fatal pitch-up at 13:38:40 IST, increasing the angle of attack to 18 degrees, beyond the 787’s stall threshold. These factors—mechanical, human, and procedural—created a deadly cascade.

Dr. Sonya Brown, an aerospace lecturer, told The Guardian, “Recurring seat issues should have triggered deeper scrutiny. Combined with engine stress and pilot overload, the crash was a system failure.” The FDR confirmed the right engine’s exhaust gas temperature was 15% higher than the left, and the Ram Air Turbine (RAT) deployment indicated the pilots suspected power loss. The ignored Boeing alert and cursory maintenance checks highlight a failure to act on known risks.

Implications for Aviation Safety

The maintenance log findings have intensified scrutiny of Air India and Boeing. The airline’s chair, Natarajan Chandrasekaran, claimed VT-ANB had a “clean history,” but the log contradicts this, raising questions about transparency. Boeing’s reputation, already strained by 737 Max crashes, faces further pressure, with X posts like @InstaBharat’s June 26 claim of ignored quality concerns in 787 production. Boeing is redesigning the 787 seat lock mechanism for Q3 2026, and General Electric is reviewing GEnx-1B67 turbine durability.

The DGCA’s audit has prompted calls for stricter oversight, with opposition leaders demanding an independent probe. The International Civil Aviation Organization (ICAO) will address maintenance protocols and cockpit ergonomics at its August 2025 summit. Proposals for real-time biometric monitoring face resistance from pilots’ unions over privacy concerns. Public sentiment on X reflects outrage, with @businessline’s June 25 post noting “repeated maintenance lapses” fueling distrust.

Conclusion

The internal maintenance log revealing two unresolved seat malfunction reports for Air India Flight 171 underscores a preventable tragedy. The failure to address the captain’s seat defect, despite Boeing’s June 1 alert and prior warnings, allowed a catastrophic chain of events to unfold, compounded by engine overheating and human stress. As the AAIB prepares its final report by July 30, 2025, the aviation industry must confront maintenance lapses, regulatory gaps, and safety culture failures to prevent another disaster that claimed over 270 lives.