The National Highway Traffic Safety Administration (NHTSA) have opened an investigation into certain 2005-2007 Corvette and Corvette Z06 vehicles after receiving thirty reports from consumers complaining of loss of headlights after 5 to 30 minutes of driving. Drivers allege that both low beam and high beam headlights stopped working simultaneously without warning impairing their ability to see the roadway safely. Some complainants reported that the problem is intermittent and some reported that low beam headlight functionality returns after a period of time, typically after the vehicle has been parked. No other lighting was affected.
General Motors (GM) provided information in response to the investigation explaining that the loss of headlights could be caused by a fractured low beam circuit wire in the bussed electrical center, a device that is similar to a fuse box. The UBEC is located in a high heat area near the engine, and the low beam circuit wire routing within the UBEC makes it susceptible to cyclical stress caused by thermal expansion.
The Office of Defects is upgrading the investigation to an Engineering Analysis to further examine the consequences, frequency and scope of this problem. If the investigation leads to a recall, an estimated 103,000 vehicles could be affected.