Air India revives long-grounded Boeing 777 after six years of inactivity

Air India has successfully revived all 30 of its previously grounded aircraft since returning to the Tata Group in 2020. One of the most notable recoveries involved VT-ALL, a Boeing 777-300ER that had been out of service for over six years. The aircraft recently took to the skies again after an extensive overhaul.

VT-ALL was first grounded in February 2020 due to multiple failing systems and ageing parts. When Tata Group reacquired Air India, 62 of the 113 aircraft in the fleet had been grounded long-term before privatisation. Efforts to restore VT-ALL began in earnest in April 2025 as part of the airline's push to expand long-haul operations.

Skilled engineering teams worked nearly around the clock to rebuild the aircraft. The restoration included a full systems overhaul—air-conditioning, landing gear, hydraulics, oxygen, avionics, and engines. Over 3,000 new key components were installed, and more than 4,000 maintenance tasks were completed. Each replacement and repair underwent strict testing and regulatory checks by India's Directorate General of Civil Aviation (DGCA), with technical support from Boeing.

The revival of VT-ALL marks a key milestone in Air India's fleet modernisation under Tata Group ownership. With all 30 previously grounded aircraft now back in service, the airline strengthens its operational capacity for long-haul routes. The project also highlights the collaboration between engineering teams, regulators, and Boeing in ensuring airworthiness.