ZKW Reflector Recall-Open NTHSA Investigation

[edlvrt]

As most of you know, and from what I gather through several internet sites in addition to my limited experience, the low beam reflectors on 2003-2004 ZKW HID headlights were made of some material that degraded when subjected to the heat produced by OEM Xenon bulbs. This results in a significant decrease in light output as the reflector became scorched. I don't know the exact ins and outs, but I would imagine that BMW and ZKW were and are aware of the defect as the newer, redesigned headlights do not suffer from this problem.

I called the National Highway Traffic Safety Administration (NHTSA) out of curiosity to see if the problem had been noted and if there was anything in the works to fix the defective parts. The gentleman that I spoke with said that an investigation of the issue was opened in 2009, closed at one point, and has been reopened. I gave him my information, VIN, and a description of the problem and the affected cars, and he told me their engineering staff would be sending me their ongoing investigation report with a questionnaire of sorts for me to return.

He told me that the more people who report the issue, the greater the chance of some sort of recall. If you suffer from the headlight issue and have a few minutes to spare, please call the NHTSA at 888-327-4236 to report a vehicle defect. If you would rather not call, there is the option to fill out an online form. Go to http://www.nhtsa.gov/ and click the blue banner to the right "Report a Vehicle or Child Seat Defect," then choose to File an Online Form and go from there.

Thanks

[kayger12]

Mount up, boys and girls.

Great info.

[az3579]

Now, for those of us that don't know what the headlights are supposed to look like, how would we test to see if we're affected? I personally have no idea how my car compares to a healthy set of ZKWs...

Sent from my DROIDX using Tapatalk

[PKR]

Let me ask a very basic question .... how does one identify / confirm the manufacturer ?

[edlvrt]

To check the manufacturer, look at the front plastic lens cover. In either the bottom left or right corner, mine say ZKW in small letters. I imagine that the other manufacturer, AL, will say AL, but I can't confirm this. It is also on the sticker on top of the light assembly, but it is likely blocked from view by the car's frame.

Checking to see if your headlights are affected can be done while the assemblies are in the car. Open your hood and remove the square rubber cap that sits behind the bulb. I have attached a picture of what my burnt reflector looks like from behind. It should be fairly obvious if yours is burnt or not.

[Marcus-SanDiego]

Mine says AL. 2005 330ci ZHP.

[danewilson77]

I have sms. I reported this last year and had forgotten about it.

Good lookin out.

HTC Thunderbolt+TT

[KC ZHP]

I have experienced this issue personally - as I understand it, all E46 ZKW zenons will likely have this issue eventually. Certainly a great deal of documentation in the forums and have seen firsthand on other similarly equipped E46s. 2004 330i ZHP sedan at 46K miles - I had LightWerkz perform the TFX retrofit in order to be able to drive the car at night as it was quite literally unsafe to drive. I chose to do the retrofit rather than dropping $1.2K on new OEM zenons with the KPD (known product defect). It's amazing to me that there has not been a recall or corrective action taken on this issue.

Justin

[billschusteriv]

Good stuff.

[Washburn]

Mine says AL. 2005 330ci ZHP.

Mark, where exactly is the spot that says 'AL' on front lens cover?