Tesla recalls 20,000 EVs over headlight glare

Tesla is recalling 20,349 Model 3 and Model Y vehicles in the US because their low-beam headlights exceed permitted luminous intensity levels in certain areas. The carmaker had sought to avoid the recall, but the US National Highway Traffic Safety Administration (NHTSA) rejected its request.

The recall specifically affects 18,735 Model Y vehicles from the 2020 to 2023 model years and 1,614 Model 3 vehicles from the 2017 to 2023 model years. Marelli Automotive Lighting supplied the headlight units fitted to these vehicles. The issue does not concern the headlights’ overall light output but specific measurement areas at the outer, upper edges of the light beam. In these areas, regulations permit a maximum of 125 candela. However, tests conducted as part of the recall documentation measured values of up to 230.1 candela. The excessive brightness could dazzle other road users and impair their vision.

The affected headlights were primarily fitted to vehicles produced before 2 June 2023. However, the components were later installed in additional vehicles, including during repairs. As a result, the recall also covers 432 vehicles with later production dates.

The issue has been a long-standing concern for Tesla and the NHTSA. As early as 2023, tests by a Canadian laboratory found that the headlights exceeded the prescribed limits. Tesla confirmed the deviation in its own investigations but did not consider the defect sufficiently safety-critical to warrant a full recall of all affected vehicles.

The manufacturer pointed out that no accidents or injuries related to the issue had been reported, although it recorded three warranty claims and one field report. Tesla subsequently applied to the NHTSA for an exemption from a full recall, but the authority rejected the request in July. As a result, Tesla must now recall all 20,349 affected vehicles.

The recall comes as the NHTSA is also scrutinising the Model 3 and Model Y in other areas. In early August, the authority launched a preliminary investigation into around 1.2 million vehicles from both model ranges. The investigation focuses on potential defects in the front lower control arm, which could lead to a loss of steering control in the worst case. The NHTSA opened the investigation after receiving 156 complaints from vehicle owners, but has not yet issued a recall.

It remains unclear how Tesla will resolve the headlight issue. The recall documentation states only that the manufacturer is currently developing a remedy. Tesla has addressed numerous recalls in the past via over-the-air updates, but there is no indication that a purely software-based solution will suffice in this case. If Tesla needs to replace the affected headlight units, owners will have to take their vehicles to a workshop.

Tesla has already informed its sales and service locations about the recall. The company expects to notify owners of the affected Model 3 and Model Y vehicles by 15 September.