Ford found the problem in May when a yellow halo condition on a Ford Edge headlight was observed at an assembly plant. Assembly employees found six right headlights with this condition and the supplier inspected the Edge headlights and confirmed four of the six headlights didn't meet federal standards "for linearity, photometric intensity, or both." From May to June 2023, Ford conducted an investigation into the supplier's production records and found that right headlights built between January 10, 2023, and January 17, 2023, could be faulty. This included 5445 headlights, a number later increased to 8,523. But in June the supplier tested 102 Ford Edge right headlights that were built between January 10, 2023, and January 17, 2023. Seven headlights didn't meet standards. As of August 2023, Ford is not aware of any warranty claims, field reports, crashes or injuries caused by the Edge headlights. Ford Edge headlight recall letters will be mailed October 9, 2023.