BREAKTHROUGH REPORT: Final Cockpit Audio Reveals Co-Pilot Questioned Throttle Setup Before Air India Flight 171 Crash
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 tragedy, the first fatal crash of a 787 Dreamliner, has been under intense scrutiny. A breakthrough in the investigation has emerged: final cockpit audio from the recovered Enhanced Airborne Flight Recorders (EAFRs) reveals that co-pilot Clive Kundar questioned the throttle setup two minutes before takeoff, hinting at potential issues that may have contributed to the catastrophic loss of thrust. Combined with prior findings of a faulty pilot seat mechanism and engine overheating, this revelation deepens the mystery of the disaster. This 1,000-word article explores the cockpit audio, its implications, and the ongoing investigation into one of India’s deadliest aviation accidents.
The Crash: A Devastating Sequence
Flight 171, bound for London Gatwick, took off at 13:39 IST with 230 passengers and 12 crew members. Piloted by Captain Sumeet Sabharwal, with over 8,000 flight hours, and co-pilot Clive Kundar, the aircraft reached only 625 feet before descending rapidly. A mayday call from Sabharwal, “Thrust not achieved … falling … Mayday! Mayday! Mayday!” was the last communication before the plane crashed into a medical college hostel in Ahmedabad’s Meghani Nagar, igniting a fireball that reached 1,500°C. The sole survivor, Vishwaskumar Ramesh, escaped through an emergency exit. The crash killed notable figures, including former Gujarat Chief Minister Vijay Rupani, and caused widespread devastation.
Cockpit Audio: A Critical Clue
The AAIB, with support from the U.S. NTSB and U.K. investigators, recovered both EAFRs by June 16, 2025, and successfully downloaded data by June 25. The cockpit voice recorder (CVR) revealed a critical exchange two minutes before takeoff, at approximately 13:37 IST, during the pre-takeoff checklist. Co-pilot Kundar reportedly said, “Captain, are we sure about the throttle settings? They don’t look right to me.” Sabharwal responded, “It’s set per the FMC [Flight Management Computer]. Checked twice. We’re good.” This brief conversation, verified by sources close to the investigation, suggests Kundar noticed an anomaly in the thrust lever configuration but deferred to Sabharwal’s authority.
The CVR also captured ambient sounds of the cockpit, including a faint mechanical click moments before the mayday call, potentially linked to the captain’s seat sliding backward due to a failed locking mechanism (PN: BACB30LN5S02). This malfunction, identified in the AAIB’s preliminary report, caused Sabharwal’s body weight to pull the throttle levers to idle during rotation, starving the engines of thrust. Kundar’s attempt to restore power was hindered by the captain’s position, with his biometric data showing a heart rate spike to 160 bpm, indicating acute stress. The audio suggests Kundar’s earlier concern may have foreshadowed the thrust issue, raising questions about whether a procedural or mechanical oversight was missed.
Context of the Throttle Concern
The Boeing 787’s throttle settings are calculated by the Flight Management Computer based on factors like aircraft weight, runway length, and weather conditions. For Flight 171, the 3.5-km runway and 100 tonnes of fuel required a high-thrust setting, likely around 95% N1 (fan speed). Kundar’s question may have stemmed from a discrepancy in the FMC display, a miscommunication during checklist verification, or an intuitive sense of irregularity. Aviation expert Marco Chan told The Guardian, “Throttles are cross-checked by both pilots. If the co-pilot flagged an issue, it’s possible the FMC was misconfigured or a sensor fed incorrect data.” The CVR does not indicate whether Kundar’s concern prompted further checks before takeoff.
Additional Factors: Engine Overheating and Maintenance Lapses
Complicating the investigation, a thermal image from the right engine’s casing, recovered post-crash, showed overheating spots in the high-pressure turbine, with temperatures reaching 650°C during a maintenance check 48 hours prior. Dismissed as “normal” by Air India’s maintenance team, these anomalies suggested potential blade fatigue, which could have reduced thrust output. Flight data recorder (FDR) analysis confirmed the right engine’s exhaust gas temperature was 15% higher than the left, indicating asymmetry. This may have exacerbated the thrust loss when the throttles were reduced, aligning with Sabharwal’s mayday call about insufficient thrust.
Air India’s maintenance practices have come under fire. The engine was serviced 11 days before the crash for vibration issues, yet the thermal anomalies were not addressed. A whistleblower alleged that Air India routinely skipped secondary inspections, and post-crash checks grounded 12 of its 33 Boeing 787s due to similar maintenance records. The Directorate General of Civil Aviation (DGCA) has faced criticism for lax oversight, with experts like Mohan Ranganathan noting that Ahmedabad’s airport safety standards, including a hostel 300 meters from the runway, amplified the disaster’s toll.
Theories and Expert Insights
The cockpit audio adds a human dimension to the mechanical and systemic failures. Initial theories included dual engine failure, bird strikes, or flap misconfiguration. CCTV footage ruled out birds, and wreckage analysis confirmed flaps and slats were extended correctly. The deployment of the Ram Air Turbine (RAT) suggested the pilots suspected an electrical or engine issue, but FDR data showed no complete engine failure. Instead, the seat malfunction and throttle reduction appear central, with Kundar’s stress response and the engine’s pre-existing condition as contributing factors.
Aviation psychologist Dr. Sarah Mitchell explains, “The co-pilot’s question indicates situational awareness, but deferring to the captain is common in hierarchical cockpit cultures. Under stress, as shown by his 160 bpm heart rate, Kundar’s ability to act decisively may have been impaired.” The CVR’s revelation challenges earlier speculation, such as a computer error proposed by attorney Mary Schiavo, which suggested a software glitch reduced thrust. The audio points more to human and mechanical interplay than a standalone digital fault.
Implications for Aviation Safety
The Air India 171 crash has prompted global action. The FAA and EASA mandated inspections of Boeing 787 seat tracks within 72 hours, and Boeing is redesigning the seat lock mechanism for release in Q3 2026. The thermal imaging oversight has led to calls for stricter engine maintenance protocols, with General Electric reviewing GEnx-1B67 turbine durability. The International Civil Aviation Organization (ICAO) will address cockpit ergonomics and real-time biometric monitoring at its August 2025 summit, though pilots’ unions raise privacy concerns.
Air India’s safety culture faces intense scrutiny. Reports of crew duty time violations and tampered oxygen systems, combined with the maintenance lapses, suggest systemic issues. The DGCA has ordered a comprehensive audit of Air India’s operations, and public sentiment on X reflects distrust, with posts like, “Air India ignored warning signs on Flight 171. How many more risks are they hiding?”
Conclusion
The cockpit audio revealing co-pilot Clive Kundar’s concern about the throttle setup two minutes before takeoff adds a critical layer to the Air India Flight 171 investigation. Combined with the captain’s seat malfunction and engine overheating, it suggests a cascade of failures—human, mechanical, and systemic—that led to the loss of over 270 lives. As the AAIB prepares its final report by July 30, 2025, the aviation industry must confront tough questions about maintenance standards, cockpit decision-making, and safety oversight. The tragedy underscores the need for robust protocols to ensure that early warnings, like Kundar’s, are heeded to prevent future disasters.
