Air India has launched an ambitious USD 400 million fleet retrofit program to upgrade the avionics and critical components of its 26 legacy B787-8 Dreamliner aircraft, addressing recent operational challenges and enhancing overall reliability. The initiative, part of the Tata Group-owned airline’s broader modernization efforts, began with the first Dreamliner sent to Boeing’s facility in Victorville, California, in July 2025. A second aircraft is slated for retrofit in October, with both expected to resume service by December 2025.
The Reliability Enhancement Programme involves a comprehensive analysis of maintenance and configuration records for the 26 B787-8s, followed by modifications aligned with Boeing’s latest service bulletins. This upgrade, targeting avionics and critical systems, aims to minimize operational disruptions for Air India and its passengers. Seven of these aircraft will also undergo heavy scheduled maintenance (D-checks) at Victorville, ensuring long-term operational excellence. The retrofitted Dreamliners will feature a modern three-class configuration—Business, Premium Economy, and Economy Class—enhancing passenger comfort. The program is set to conclude by mid-2027.
Air India’s modernization extends beyond the Dreamliners. Starting in early 2027, the airline will retrofit 13 legacy Boeing 777-300ER aircraft, with completion expected by October 2028, despite supply chain delays. Additionally, the retrofit of 27 legacy A320neo aircraft, initiated in September 2024, is on track for completion by September 2025, with 16 already upgraded. Air India has also reversed plans to retire its 13 legacy A321ceo planes, opting to retrofit them instead.
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The airline’s 33 Dreamliners—26 B787-8s and seven B787-9s—underwent thorough inspections, including fuel switch checks, following a tragic crash of a London Gatwick-bound B787-8 on June 12, 2025, which claimed 260 lives. With a fleet of approximately 190 narrow-body and wide-body aircraft, Air India’s comprehensive retrofit strategy underscores its commitment to safety, reliability, and an elevated travel experience.
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