Fiat 500e Recall Issued for Headlamp Aiming Issue That Could Affect Visibility

Chrysler (FCA US, LLC) is initiating a voluntary safety recall for certain 2024 and 2025 model year Fiat 500e Battery Electric Vehicles (BEVs) due to a potential noncompliance with Federal Motor Vehicle Safety Standard (FMVSS) No. 108. According to information submitted to the National Highway Traffic Safety Administration (NHTSA), the vehicles may have been manufactured without the necessary plugs for the horizontal headlamp aim adjustment mechanism. This condition could lead to improper headlamp aim, potentially reducing forward visibility for the driver and causing glare for oncoming drivers, which could result in a vehicle crash.

The recall affects approximately 2,195 Fiat 500e vehicles produced between November 2, 2023, and May 23, 2025. The issue stems from an engineering oversight where the plugs for the horizontal headlamp aim adjustment were not installed during production. While there is no defect in a specific part, the accessibility of this adjustment mechanism is the cause of the noncompliance. The identified components for this recall are the caps used for the horizontal headlamp aim adjustment, with part number 68765152AA. The supplier of these components is Marelli Automotive Lighting Italy S.p.A., located in Italy.

The potential safety risk arises if the headlamp aim is improperly adjusted. This could lead to compromised forward illumination for the driver and a greater risk of dazzling other motorists, potentially leading to accidents without prior warning. There are no specific warnings that can occur to alert drivers to this condition. To address this issue, Chrysler will conduct a repair that involves installing a plug to cover the horizontal headlamp aim adjustment opening. This remedy ensures that the adjustment mechanism will no longer be accessible, thereby correcting the noncompliance with FMVSS No. 108.

The chronology of events leading to this recall began on May 20, 2025, when a potential issue regarding headlamp aim adjustment accessibility was identified during a read-across related to Fiat 500e vehicles. An investigation was formally opened on July 15, 2025, by Stellantis Europe S.p.A Control Tower, which involved detailed reviews with engineering and manufacturing teams to understand the failure mode and determine the scope of affected vehicles. By October 8, 2025, the existence of a vehicle build issue related to the headlamp adjustment mechanism was recognized, and on October 14, 2025, it was determined that a noncompliance with a Federal Motor Vehicle Safety Standard existed in certain vehicles.

Chrysler will notify dealers about the recall on or about October 28, 2025, and owners are expected to be notified starting around December 10, 2025. The VINs of affected vehicles will be searchable beginning October 28, 2025. Owners are advised not to drive the vehicles if possible and to park them outside until the repair is completed. Chrysler has a general reimbursement plan on file for any expenses incurred related to this recall.

Article by Mel Anara, based upon information from Chrysler (FCA US, LLC)

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