NHTSA Complaint #10837350 — 2004 MERCEDES BENZ ML350

DURING A ROUTINE CHANGE OF A HEADLIGHT LAMP, THE MAINTENANCE TECHNICIAN DISCOVER THAT THE INSULATION ON ALL FOUR WIRES IN THE LEFT FRONT HEADLIGHT ASSEMBLY WERE CRACKED, DISINTEGRATING AND MISSING LEAVING THE BARE WIRES EXPOSED. THE MAINTENANCE TECHNICIAN WOULD NOT CHANGE THE BULB UNTIL A NEW WIRING HARNESS WAS FABRICATED AND THE DISCREPANCY WAS CORRECTED. THIS IS A DANGEROUS SITUATION. THE BARE WIRES ARE IN AN ENCLOSED HEADLAMP ASSEMBLY, CONTACTING FLAMMABLE MATERIALS. A SHORT IN THESE WIRES CAN LEAD TO SYSTEM FAILURES, OVERHEATING AND FIRE IN THE HEADLAMP AREA. RECOMMEND A RECALL FOR INSPECTION AND IF THIS DISCREPANCY IS DISCOVERED, RECOMMEND AN IMMEDIATE REPLACEMENT OF THE WIRES IN THE HEADLAMP ASSEMBLY.