Air India has completed the revival of its legacy grounded fleet, marking a significant milestone in its post-privatisation transformation under the Tata Group. When the airline returned to the Tata Group in 2022, rebuilding its fleet and restoring operational capabilities were among its primary priorities. At the time, Air India had inherited 113 aircraft, including 30 widebody and narrowbody aircraft that had remained grounded for several years.
With the return to service of VT-ALL, a Boeing 777-300ER and the last of the 30 grounded aircraft, the airline has concluded this phase of its fleet restoration programme. The aircraft, along with other Boeing 777s in the fleet, is slated to undergo a full retrofit starting in 2027, which will introduce upgraded cabins, new seats, modern amenities, and the airline’s updated livery.
VT-ALL had been grounded since February 2020 due to multiple technical issues and ageing components. In April 2025, Air India initiated efforts to restore the aircraft to operational condition to support its long-haul expansion plans. The aircraft entered the AIESL MRO facility in Nagpur in May 2025, where it underwent an extensive restoration programme.
The process involved the installation of more than 3,000 components and the completion of over 4,000 maintenance tasks, including around 80 mandated modifications such as structural reinforcements. Major assemblies including engines, auxiliary power unit (APU), and key external components were replaced. Additionally, critical systems, ranging from air-conditioning and hydraulics to avionics and landing gear, were rebuilt and tested.
The airline said that the restoration was carried out under regulatory oversight by the Directorate General of Civil Aviation (DGCA), with technical guidance from Boeing. Multiple teams across Air India, including maintenance, engineering, planning, and quality assurance, collaborated on the project.
The aircraft has successfully completed its test flight and has been granted the Airworthiness Review Certificate (ARC), confirming compliance with safety requirements for commercial operations.
