Tesla knew some of its headlights were twice as bright as legally allowed, now it's recalling 20,000 vehicles

Tesla has initiated a recall of more than 20,000 vehicles due to low-beam headlights exceeding legal brightness limits. The issue, discovered in March 2024 while preparing a separate Canadian recall, affects 1,614 Model 3 sedans and 18,735 Model Y crossovers. Manufactured between July 2017 and December 2023, these vehicles' headlights, supplied by Marelli Automotive Lighting, produced light output more than twice the maximum legal intensity in certain areas of the low-beam pattern.

The NHTSA warned that this excess light could cause glare, particularly during adverse weather conditions like rain, fog, or snow, increasing the risk of a crash. Despite Tesla's argument that the noncompliance posed no safety risk and had not resulted in any complaints, crashes, or injuries, the agency disagreed and denied the automaker's petition to avoid notifying owners or providing a remedy.

Tesla is currently developing a remedy for the headlights, and owner notification letters will be mailed starting September 15.