Air India to upgrade avionics, critical components of Dreamliners to reduce operational issues

Air India on Sunday said it will upgrade the avionics and other critical components of its 26 legacy B787-8 Dreamliner aircraft to reduce operational disruptions as well as improve overall reliability.

In recent times, the airline has faced operational issues with some of its planes, including the Dreamliner.

Air India's Dreamliners -- 26 legacy 787-8s and seven 787-9s -- had undergone checks, including that of fuel switches, after the fatal crash of a London Gatwick-bound 787-8 plane soon after take-off from Ahmedabad that killed 260 people on June 12.

Under the USD 400 million fleet retrofit programme announced in December 2022, the Tata Group-owned airline has now started the retrofit of the first legacy Dreamliner, which was flown to a Boeing facility in Victorville, California, in July 2025.

"A second aircraft is scheduled to depart for the same facility in October 2025, with both expected to return to service in December 2025," the carrier said in a statement on Sunday.

As part of a Reliability Enhancement Programme, the airline said it will be upgrading the avionics and other critical components of the 26 legacy B787-8 aircraft up to the latest industry standards, thus improving their reliability.

"The programme entails the analysis of maintenance and configuration records for these aircraft, followed by the implementation of recommended modifications based on Boeing's service information bulletins.

"This is intended to reduce operational disruptions for both Air India and its customers," the statement said.

Additionally, the airline said seven of the 26 B787-8s will undergo heavy, scheduled maintenance (D-checks) at Victorville, ensuring the fleet's long-term operational excellence.

The retrofit of the legacy Dreamliners is expected to be completed by mid-2027 and the retrofitted planes will have a three-class configuration -- Business, Premium Economy and Economy Class seats.

"Starting in early 2027, Air India will additionally retrofit 13 of its legacy Boeing 777-300ER aircraft, aiming for completion by October 2028, with the timeline having shifted due to supply chain delays," the statement said.

Air India has around 190 narrow-body and wide-body planes.

The airline's retrofit programme for 27 legacy A320 neo aircraft that commenced last September is expected to be completed in September this year.

So far, 16 A320neo aircraft have been retrofitted.

Air India has also decided to retrofit its 13 legacy A321 ceo planes that were earlier planned to be taken out of service.