Overly bright headlights: Tesla recalls 20,000 electric vehicles

Tesla must recall 20,349 Model 3 and Model Y vehicles in the U.S. In these affected cars, the high-beam headlights exceed the allowed brightness levels in certain areas. Tesla attempted to avoid the recall, but the U.S. Transportation Safety Administration, NHTSA, rejected its request.

The recall specifically covers 18,735 Model Y vehicles from model years 2020 to 2023, as well as 1,614 Model 3 vehicles from model years 2017 to 2023. These vehicles were equipped with certain headlight units supplied by Marelli Automotive Lighting. The issue does not affect the overall brightness of the headlights but rather specific measurement areas on the outer upper edges of the light beam, where a maximum of 125 candela is allowed. However, tests conducted according to the recall documents showed values as high as 230.1 candela. This could blind other road users and impair their visibility.

The affected headlights were primarily installed in vehicles manufactured before June 2, 2023. However, these components later ended up in other vehicles as well, including during repairs. A total of 432 vehicles with later production dates are also believed to be affected.

The issue has been troubling Tesla and the NHTSA for some time. As early as 2023, tests conducted by a Canadian laboratory revealed that the headlights exceeded the specified values. Tesla confirmed the deviation in its own investigations but deemed the defect not serious enough to warrant a recall of all affected vehicles. The manufacturer pointed out, among other things, that no accidents or injuries related to the problem had been reported. However, three warranty claims and one field report were recorded. Therefore, Tesla requested the NHTSA to allow it to avoid a full recall. The agency rejected this request in July, meaning all 20,349 affected vehicles must now be recalled.

The recall comes at a time when the NHTSA is conducting more detailed investigations into the Model 3 and Model Y elsewhere. It was only in early August that it became known the agency had launched a preliminary investigation into around 1.2 million vehicles of both models. The issue concerns possible defects in the front lower control arm, which could lead to loss of steering control in the worst cases. The investigation was triggered by 156 complaints from vehicle owners. No recall has resulted from these complaints so far.

It is still unclear how Tesla will resolve the headlight issue. The documents only state that a remedy is currently being developed. This is notable because Tesla has been able to handle numerous recalls in the past through over-the-air updates. In this case, there is no indication yet that a purely software-based solution will suffice. If replacing the affected headlight units becomes necessary, the vehicles will have to be taken to a dealership for repairs.

Tesla has already informed its sales and service locations about the recall. Owners of the affected Model 3 and Model Y vehicles are expected to receive notification by September 15.