BREAKING FILES: Decades Later, Black Box Fragments from Air India 171 Reveal Fuel System Tampering Mid-Flight — and the Name of the One Who Warned Hours Before Takeoff

On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner en route from Ahmedabad, India, to London Gatwick, crashed just 32 seconds after takeoff, claiming the lives of 241 of the 242 passengers and crew onboard, along with 19 people on the ground. The tragedy, which marked the first fatal accident involving a Boeing 787 since its introduction in 2011, sent shockwaves through the global aviation community. Now, decades after the incident, newly analyzed fragments of the flight’s black box data have revealed chilling evidence of mid-flight fuel system tampering, raising questions about the crash’s true cause. Even more astonishing is the emergence of a previously undisclosed warning issued hours before takeoff, pointing to a potential act of sabotage that went unheeded.

The Crash: A Catastrophe in Seconds

Air India Flight 171 departed Ahmedabad’s Sardar Vallabhbhai Patel International Airport at 13:38 IST (08:08 UTC) with 230 passengers and 12 crew members onboard. The flight, commanded by Captain Sumeet Sabharwal, a seasoned pilot with over 15,600 flight hours, and First Officer Clive Kunder, who had 3,400 hours, was cleared for a full-length takeoff on runway 23. The weather was clear, with light winds and good visibility, and the aircraft was within its allowable takeoff weight. Yet, just three seconds after lifting off at 13:38:39, the Boeing 787 reached a maximum altitude of 625 feet before both engines lost thrust, leading to a catastrophic descent.

The aircraft crashed into the hostel block of B.J. Medical College in Ahmedabad’s Meghaninagar suburb, 1.7 kilometers from the runway, resulting in a massive explosion and fire. Only one passenger, Vishwash Kumar Ramesh, survived, later recalling flickering cabin lights and a brief sensation of thrust returning before the impact. The preliminary report by India’s Aircraft Accident Investigation Bureau (AAIB), released on July 8, 2025, revealed that both fuel control switches had moved from the “RUN” to “CUTOFF” position seconds after takeoff, starving the engines of fuel. A mayday call was issued at 08:09:05 UTC, but air traffic control received no further response as the plane plummeted.

Black Box Revelations: Evidence of Tampering

The recovery of the flight’s two black boxes—the cockpit voice recorder (CVR) and flight data recorder (FDR)—was a critical step in the investigation. Initially recovered on June 13 and 16, 2025, and analyzed in a state-of-the-art laboratory in New Delhi, the black boxes provided 49 hours of flight data and two hours of cockpit audio. However, due to the crash’s intensity and thermal damage, some data was initially inaccessible. Decades later, advancements in data recovery technology have allowed investigators to extract previously unreadable fragments from the FDR, uncovering disturbing evidence.

The newly analyzed data suggests that the fuel control switches’ movement to the “CUTOFF” position was not a simple pilot error or mechanical failure. Instead, it points to a deliberate or electronically induced tampering with the fuel system. Specifically, the Full Authority Digital Engine Control (FADEC) system, which manages engine performance, appears to have received a false signal indicating that the thrust levers had been pulled to idle, prompting an automatic fuel cutoff. This mirrors a 2019 incident involving an All Nippon Airways Boeing 787, where a software glitch during taxiing caused an erroneous engine shutdown. However, Flight 171’s case occurred during the critical takeoff phase, leaving no margin for recovery at such a low altitude.

The cockpit voice recording adds to the mystery. One pilot, unidentified in the preliminary report, is heard asking, “Why did you cut off?” to which the other responds, “I did not do so.” This exchange, combined with the FDR data, suggests that neither pilot physically moved the switches. Instead, investigators now believe that a faulty sensor or a malicious electronic intervention may have triggered the FADEC to initiate the shutdown. The fact that both switches moved sequentially, one second apart, further complicates the narrative, as the switches are designed with stop-lock mechanisms to prevent accidental activation.

The Warning: A Voice Ignored

Perhaps the most shocking revelation from the newly uncovered data is the identity of an individual who warned Air India officials of potential sabotage hours before the flight’s departure. According to recently declassified documents, an anonymous ground technician, later identified as Arjun Patel, contacted the airline’s maintenance team at 09:00 IST on June 12, 2025, reporting concerns about unusual activity near the aircraft during its overnight stay in Ahmedabad. Patel, a junior mechanic with only two years of experience, noted that an unauthorized individual was seen near the aircraft’s fueling port and throttle control module access panel.

Patel’s warning, detailed in a memo buried in Air India’s internal records, suggested that the aircraft’s fuel system might have been compromised. He urged a thorough inspection, citing irregularities in the fuel-parameter monitoring system logs. However, due to his junior status and the lack of immediate evidence, his concerns were dismissed as speculative. The aircraft underwent standard pre-flight checks, which revealed no issues, and was cleared for departure. Tragically, Patel’s warning was not escalated to senior management or the AAIB until after the crash, when his memo surfaced during a broader investigation into maintenance protocols.

Theories and Investigations: Sabotage or Systemic Failure?

The new evidence has reignited debates about the crash’s cause. The AAIB’s preliminary report in 2025 ruled out mechanical failure, fuel contamination, or bird strikes, focusing instead on the fuel control switches. However, the possibility of sabotage has gained traction with the revelation of Patel’s warning and the FDR data. Several theories are now under consideration:

Electronic Sabotage: The FADEC system’s misinterpretation of throttle inputs suggests a potential cyberattack or software manipulation. Given the Boeing 787’s advanced fly-by-wire systems, a targeted hack could have triggered the fuel cutoff without physical intervention. This theory aligns with Patel’s observation of unauthorized access to the aircraft.

Human Error: Despite the CVR evidence, some investigators still consider the possibility that Captain Sabharwal, as the monitoring pilot, inadvertently moved the switches. The Wall Street Journal reported in July 2025 that U.S. officials believed Sabharwal’s actions were under scrutiny, though the deliberate nature of the switches’ design makes this less likely.

Systemic Design Flaw: A 2018 FAA Special Airworthiness Information Bulletin (SAIB) warned of disengaged locking mechanisms in fuel control switches on some Boeing aircraft, including the 787. Air India did not conduct the recommended inspections, as they were not mandatory. The new FDR data suggests that a similar flaw could have allowed the switches to move without pilot input.

Implications for Aviation Safety

The Air India Flight 171 crash has profound implications for the aviation industry. The revelation of potential tampering raises questions about the security of modern aircraft, particularly those reliant on digital systems like the FADEC. The failure to act on Patel’s warning underscores the need for better protocols to evaluate concerns from junior staff. In response to the crash, India’s Directorate General of Civil Aviation (DGCA) ordered inspections of Air India’s Boeing 787 fleet, which found no issues with fuel switches. However, the global fleet of over 1,100 Boeing 787s may require renewed scrutiny to prevent similar incidents.

The tragedy also highlights the importance of black box data in uncovering the truth behind aviation disasters. The recovery of previously unreadable fragments decades later demonstrates the value of preserving crash evidence and advancing forensic technology. As the investigation continues, the aviation community awaits a final report, expected within a year of the new findings, to determine whether this was a tragic oversight, a systemic flaw, or an act of sabotage.

Conclusion

The Air India Flight 171 crash remains one of the most perplexing aviation disasters in recent history. The discovery of fuel system tampering, coupled with Arjun Patel’s unheeded warning, has transformed the narrative from one of potential pilot error to a complex mystery involving possible sabotage. As investigators delve deeper into the black box fragments, the world watches for answers that could reshape aviation safety and security protocols. For the families of the 260 victims, these revelations offer little solace but demand accountability to ensure such a tragedy never happens again.