NHTSA complaint #11766258

Owner complaint summary

The headlight assemblies, both headlights, (headlamp housing) failed due to structural factory stress fracturing. The polycarbonate outer lens has developed clean, horizontal hairline cracks originating directly from the sealed lower edge where the housing meets the internal bumper brackets. This structural failure has breached the factory seal, causing severe water pooling inside the light assembly. Yes, the vehicle and the failing component are available for inspection upon request. The severe water accumulation inside the headlamp assembly poses an immediate night-driving safety hazard. Moisture intrusion directly exposes critical electrical connections and LED components to pooling water, risking a sudden, catastrophic short-circuit and total headlight failure while driving at night. This would instantly compromise forward visibility and reduce the vehicle's visibility to oncoming traffic. Yes. The physical water accumulation and the structural hairline cracks were confirmed during a physical inspection at an authorized Genesis dealership service center. The dealership confirmed the presence of the moisture breach but attributed the damage to external influence, despite a total lack of any external impact marks. Yes, it has been inspected by the manufacturer. Visual photographic evidence of the failing headlamp component was formally escalated to Genesis Corporate Customer Care (Case #43274801). The corporate case manager conducted a digital review of the component and subsequently sided with the local dealership's denial of warranty coverage. There were no dashboard warning lights or prior to the failure. The first physical symptom appeared (cracks) appeared recently, but condensation was present at purchased. Upon closer inspection of the pooling water, the clean horizontal stress fractures along the bumper seam became visible.