Sources said the development marked a significant milestone in Air India’s transformation journey.
Tata Group-promoted Air India has brought back into service all 30 previously grounded aircraft inherited at the time of its privatisation raising its current fleet strength to 186 aircraft, industry sources told businessline.
With the return to service of Boeing 777-300ER VT-ALL, all the long-grounded aircraft, 19 narrowbody and 11 widebody, have been restored and joined the fleet.
Sources said the development marked a significant milestone in Air India’s transformation journey.
At the time of privatisation, Air India had inherited a total of around 110 legacy aircraft of which as many as 30 were long-grounded.
Notably, the VT-ALL will now go for a comprehensive $400 million retrofit programme from 2027.
Sources said at the time of Air India’s return to the Tata Group in 2022, rebuilding the fleet and restoring operational capability were identified as a “key priority.”
Post-privatisation, Air India committed resources to revive each of these aircraft as part of its broader operational restoration programme.
When contacted, Air India’s Chief Operations Officer, Captain Basil Kwauk, acknowledged the development stating that that Boeing 777-300ER, VT-ALL, is back into service.
“It is the last of the 30 grounded aircraft and bringing this aircraft back into service basically delivers a promise, that we once said that we will bring all grounded aircraft back and today Air India delivers,” he told businessline.
VT-ALL had remained grounded since February 2020 due to multiple unserviceable systems, ageing components and non-availability of key components and spares.
In April 2025, Air India initiated restoration work to bring this aircraft back into operational service in support of its long-haul network expansion.
The aircraft entered the MRO facility in Nagpur for the nose-to-tail overhaul May 2025, where it underwent an extensive restoration programme.
It is learnt that more than 3,000 key components were installed during the process, along with completion of over 4,000 maintenance tasks.
These included around 80 mandated modifications, among them the Longeron Modification, which involves a major structural reinforcement of the aircraft.
Additionally, major assemblies were replaced, including engines, the auxiliary power unit, inlet and fan cowls and thrust reverser cowls. Both the left-hand and right-hand engines were replaced as part of the restoration.
Besides, the aircraft underwent comprehensive systems rebuild covering air-conditioning, landing gear, hydraulics, oxygen systems, avionics and engine systems.
Furthermore, each repair and modification was carried out under regulatory oversight by the Directorate General of Civil Aviation (DGCA), with technical guidance from Boeing.
The airline said that the aircraft has now completed its validation phase, which included system checks under operational conditions, detailed inspections and test flights.
Meanwhile, VT-ALL has received the Airworthiness Review Certificate, a mandatory certification confirming that the aircraft meets the safety parameters required to commence regular operations.
Published on March 17, 2026
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