The Hidden Dangers of Recalled Panels
October 27, 2025
A Safety Message from Dollens Electric — San Jose’s Trusted Electricians
At Dollens Electric, your family’s safety always comes first. For decades, our licensed electricians have helped San Jose and Bay Area homeowners stay safe by inspecting and replacing outdated electrical panels — and three names come up again and again: Challenger, Zinsco, and Federal Pacific Electric (FPE).
While these panels may look fine from the outside, they can hide internal defects that have been linked to increased risks of electrical fires, shock hazards, and property damage. If your home still uses one of these models, here’s why you should consider an electrical panel upgrade as soon as possible.
Why Your Electrical Panel Is So Important
Your breaker panel is your home’s main electrical control center. It distributes power to every outlet, light, and appliance — and it’s designed to trip (shut off) when something goes wrong.
When a breaker fails to trip during an overload or short circuit, your wiring can overheat, leading to fire. Unfortunately, that’s been documented to happen with certain Challenger, Zinsco, and Federal Pacific panels.
Challenger Panels (1980s–1990s)
The concern:
Challenger panels, found in many homes built in the 1980s and 1990s, have been reported to contain defective breakers that may overheat, melt, or fail to trip properly.
Common issues electricians observe:
Breakers that do not shut off during overloads
Scorch marks or melted bus bars inside the panel
Loose internal connections that create arcing and heat damage
If your electrical panel says “Challenger” or “Eaton/Challenger,” schedule an inspection right away. Panel replacement is generally the safest and most reliable solution.
Zinsco Panels (1950s–1970s)
The concern:
Zinsco (and Sylvania-Zinsco) panels have been identified by electricians and inspectors as having poor internal connections. Their breakers can lose contact with the bus bar and sometimes fuse permanently, meaning they can’t shut off even when overloaded.
Warning signs:
Breakers that appear “off” but still conduct power
Melted aluminum bus bars or discoloration
Electrical shocks or flickering lights
Because of these known design flaws, most electricians — including our team at Dollens Electric — recommend Zinsco panel replacement as a top safety priority.
Federal Pacific Electric (FPE) Panels (1950s–1980s)
The concern:
Federal Pacific panels, especially those using Stab-Lok breakers, have been linked in multiple independent tests and safety reports to higher-than-normal breaker failure rates.
Why they’re considered unsafe:
Breakers that appear functional but may not trip properly
Hidden arcing and overheating inside the panel
Many insurance companies will not cover homes with FPE panels
At Dollens Electric, we’ve seen firsthand instances where these panels failed to trip properly, underscoring the importance of professional inspection. Replacing an FPE panel with a modern, UL-listed breaker panel greatly reduces your risk of fire.
Repair vs. Replace: Why Replacement Is the Only Safe Choice
What Bay Area Homeowners Should Do
Even though replacement costs more than repair, it’s the only reliable fix. These panels have inherent design weaknesses— swapping out breakers doesn’t eliminate the danger.
Upgrading to a modern electrical panel gives you:
Safe, reliable breaker protection
Higher capacity for today’s power demands
Better home insurance approval
Long-term peace of mind
Check your panel’s brand name — look for Challenger, Zinsco, Federal Pacific, or Stab-Lok.
Schedule a safety inspection with a licensed electrician.
Plan for an electrical panel replacement if your home uses one of these outdated systems.
Our electricians will help you choose the right panel for your home, handle all permits, and complete your upgrade safely and efficiently.
Electrical Panel Recalls & Safety Alerts Every Homeowner Should Know
When it comes to home safety, few things are as critical as your main electrical panel. Outdated or recalled panels can overheat, arc, or even catch fire — often without warning. Below are verified recall notices and official resources from the U.S. Consumer Product Safety Commission (CPSC), Electrical Safety Authority (ESA), and manufacturers themselves.
Major U.S. Recalls
1. Schneider Electric / Square D QO Plug-on-Neutral Load Centers
Recall Date: June 2022
Hazard: Loose neutral connections can cause overheating, thermal burns, and fire risk.
Affected: Units manufactured Feb 2020 – Jan 2022, date codes 200561–220233.
Details:
2. Siemens / Murray Circuit Breakers & Load Centers
Recall Date: June 2010
Hazard: Breakers can fail to trip in overload conditions, creating a fire risk.
Details:
3. Challenger Electrical Equipment Panels (Older Models)
Status: Not an active recall, but known to have breaker contact failures and overheating hazards.
Recommendation: Replace or have a licensed electrician inspect for heat damage and corrosion.
Panels With Documented Safety Issues (No Formal Recall but Industry Advisories)
Federal Pacific Electric (FPE) / Stab-Lok Panels
Known for breakers failing to trip under overload conditions.
Zinsco / GTE-Sylvania Panels
Common in mid-century homes; bus bars often melt or arc.
ITE Pushmatic Panels
Outdated mechanical design; breakers can seize or fail to reset.
