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decades, our licensed electricians have helped San Jose and Bay Area homeowners stay safe by inspecting and replacing outdated electrical panels — and three names come up again and again: Challenger, Zinsco, and Federal Pacific Electric (FPE).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
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
🛠️ What Bay Area Homeowners Should Do
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.
✅ Trust Dollens Electric — San Jose’s Electrical Panel Experts
At Dollens Electric, we’re committed to keeping Bay Area homes safe, energy-efficient, and up to modern electrical code. Whether you need a panel inspection, panel upgrade, or breaker box replacement, our certified electricians will handle your project with professionalism and care.
Don’t wait until you smell burning wires or experience a power issue — some panels can fail silently.
📞 Call Dollens Electric today or schedule your electrical panel inspection online to protect your home and your family.
(408) 929-6100
🔍 Recall Information
Federal Pacific (FPE): The U.S. Consumer Product Safety Commission (CPSC) investigated FPE panels but did not issue a formal recall. Independent testing, however, found elevated failure rates.
Challenger: A limited 1988 recall was issued for certain GFCI breakers.
Zinsco: No formal recall exists, but safety concerns are well-documented in the electrical industry.
