When Air India returned to the Tata Group in 2022, one of the airline’s biggest priorities was rebuilding its fleet. Among the inherited legacy fleet of 113 aircraft were 30 widebody and narrowbody aircraft that had remained long‑grounded and untouched for years. Post-privatisation, Air India committed significant resources to revive each of them.
With the return of VT-ALL to service, a Boeing 777‑300ER, the final chapter of this revival effort is now complete. After the retrofit, due to start next year, the Boeing 777-300ERs will offer the new Air India experience while sporting the airline’s new livery.
A comeback 6 years in the making
VT‑ALL has been grounded since February 2020 due to multiple unserviceable systems and aging components. In April 2025, Air India initiated efforts to bring it back to full operational life to support long‑haul expansion. The aircraft entered the AIESL Nagpur MRO facility in May 2025, beginning an intensive, nose‑to‑tail restoration programme.
– 3,000+ new key components installed – an undertaking rarely seen outside of deep structural overhauls
– 4,000+ maintenance tasks completed, including 80 mandated modifications such as the complex Longeron Modification, a crucial structural reinforcement
– Replacement of major assemblies including engines, APU, inlet & fan cowls, and thrust reverser cowls
– A full systems rebuild – covering air-conditioning, landing gear, hydraulics, oxygen, avionics, and engine systems – essentially reconstructing the aircraft’s functional backbone
Each part replacement, system restoration, and structural repair underwent stringent testing, documentation, and regulatory oversight by DGCA, with technical guidance from Boeing.
Credits: Air India
