Tesla Recalls Over 20,000 Vehicles for Headlights That Exceed US Brightness Limits

Tesla is recalling more than 20,000 cars because their low-beam headlights are too bright for US roads. The affected models include certain 2017-2023 Model 3s and 2020-2023 Model Ys. The headlights, made by Marelli Automotive Lighting, exceed the maximum allowed intensity in the outer upper areas, which could reduce visibility for the driver and others, raising crash risk.

The recall covers 1,614 Model 3s built between July 24, 2017, and December 2, 2023, and 18,735 Model Ys built from February 11, 2020, to December 24, 2023. The issue first surfaced in Canada, where a Transport Canada compliance test in 2019 flagged a Model 3's headlights as non-compliant.

Tesla learned of the problem on January 16, 2024, and issued an initial recall in March 2024.

Tesla later petitioned the NHTSA for an exemption, arguing the fault was inconsequential to safety, but the agency denied that request about three weeks ago. Most vehicles in this new recall were already covered by the 2024 action, but Tesla added 432 more after discovering non-compliant headlights were used in service longer than expected.

A fix is still being developed.