Tesla Recalls 20,349 Model 3 and Model Y EVs Over Low-Beam Headlights Exceeding Federal Brightness Limit
Tesla has issued a physical recall covering 20,349 Model 3 and Model Y vehicles in the United States after NHTSA rejected the company's claim that excessively bright low-beam headlights were inconsequential, with affected units measuring up to 230 candela — roughly 84% above the federal ceiling.
Tesla submitted recall report 26V507 to NHTSA on 4 August 2026, initiating a physical recall of 20,349 vehicles in the United States. The action covers 18,735 pre-refresh Model Y vehicles from model years 2020 to 2023 and 1,614 Model 3 cars from model years 2017 to 2023. The defect involves low-beam headlight assemblies supplied by Marelli Automotive Lighting in Mexico, which produce excessive light output: NHTSA testing measured peak output as high as 230 candela at the relevant test point, approximately 84% above the federal upper limit.
The regulator determined that excessive low-beam output reduces visibility for both the Tesla driver and other road users, raising the risk of a crash. Tesla had initially argued the lighting variance was inconsequential and submitted a petition requesting that NHTSA classify it as such, which would have exempted the company from notifying owners and performing a recall. NHTSA rejected that petition and ordered a full physical recall.
The recall requires a physical fix — replacement of the affected headlight assemblies — and cannot be resolved by an over-the-air software update. Owners must visit a Tesla service centre for the repair. Tesla began notifying its stores and service centres on or shortly after 4 August 2026. Owner notification letters are scheduled to be mailed on 15 September 2026, although many owners are expected to receive notice through the Tesla app beforehand.