Tesla Recalls Over 20,000 Model 3 and Model Y EVs Over Headlight Brightness Issue
Tesla is recalling 20,349 electric vehicles in the United States after federal safety regulators determined that the low-beam headlights on certain Model 3 and Model Y vehicles are brighter than allowed under current safety standards.
The recall affects 18,735 Tesla Model Y vehicles built between February 2020 and December 2023, along with 1,614 Tesla Model 3 vehicles manufactured between July 2017 and December 2023. The issue involves headlamp assemblies supplied by Marelli Automotive Lighting and produced at its facility in Ciudad Juárez, Mexico.
According to the recall filing, the affected headlights exceed the permitted brightness limit in specific upper areas of the low-beam pattern. The problem does not apply to the entire beam, but rather to the upper-left and upper-right sections of a defined photometric testing zone. Federal Motor Vehicle Safety Standard No. 108 sets limits for headlamp brightness to help reduce glare and protect other road users.
Regulators found that the low-beam output in these areas could reach up to 230 candela, while the allowed maximum is 125 candela. That means some of the affected headlights may be roughly 84 percent brighter than the legal limit in the tested zone.
Tesla had previously argued that the issue should be considered minor and not safety-related. The company said the excessive light was outside the natural line of sight for drivers and stated that it had not received reports of crashes, injuries, or customer complaints linked to the headlight brightness. Tesla also maintained that glare was not a real-world concern for these vehicles.
However, the National Highway Traffic Safety Administration rejected Tesla’s request in July 2026. The agency concluded that Tesla had not shown the noncompliance to be inconsequential to vehicle safety. Regulators also raised concerns that weather conditions such as fog, rain, or snow could make glare more noticeable for oncoming drivers.
The affected headlamp assemblies are no longer in production. Tesla has already introduced updated, compliant headlight units into newer Model 3 and Model Y vehicles. Compliant lamps began appearing in Model 3 production in December 2022 and in Model Y production in August 2023 at Tesla’s Fremont and Austin factories.
For now, Tesla has not announced the final repair plan. Owners of affected Model 3 and Model Y vehicles will need to visit a Tesla service center once the remedy is available. The repair or replacement will be completed free of charge.
If Tesla decides to replace the entire headlamp unit, affected vehicles may receive the latest compliant headlights. Depending on the vehicle and part availability, some replacement units could include newer lighting hardware with matrix beam capability.
The recall comes after a lengthy review process between Tesla and federal regulators. Although the issue is limited to a specific portion of the low-beam pattern, the decision confirms that even small deviations from lighting safety standards can trigger a formal recall when regulators believe there may be a risk to other drivers.
Tesla Model 3 and Model Y owners should watch for official recall notifications and check whether their vehicle is included once the company begins contacting affected customers.
