Image: Tesla
Tesla is once again facing regulatory scrutiny in the U.S., this time over concerns tied to emergency door releases in the Model 3.
According to Reuters, the National Highway Traffic Safety Administration (NHTSA) has opened a defect investigation into Tesla Model 3 sedans amid worries that the vehicles’ emergency door release controls may not be easily accessible or clearly identifiable during an emergency. The probe covers an estimated 179,071 Model 3 vehicles from the 2022 model year and was formally opened on December 23.
The investigation stems from a defect petition alleging that the Model 3’s mechanical door release is hidden, unlabeled, and not intuitive to locate when seconds matter. While Tesla vehicles primarily rely on electronic door latches that open via buttons rather than traditional handles, they do include manual releases designed for emergencies or power failures.
However, safety experts have long raised concerns that these mechanical releases are not consistently visible or clearly marked — especially for rear-seat passengers. Notably, that’s not the case for vehicles produced at Tesla’s Chinese Gigafactory in Shanghai as of February 2025, which have clear emergency door handle markings on the mechanical release. Take a look at a comparison image below:
At this stage, the opening of a defect petition does not mean a recall is imminent. Instead, it represents the first step in a broader regulatory review process that could lead to further action if the NHTSA determines a safety-related defect exists.
This latest probe adds to a growing list of regulatory and legal challenges surrounding Tesla’s door designs. Just last month, the automaker was sued over a fatal Wisconsin crash involving a Model S, where all five occupants were allegedly trapped inside a burning vehicle due to door design issues. Tesla has also been sued by the families of two college students killed in a Cybertruck crash last year, with similar allegations that occupants were unable to exit the vehicle.
NHTSA scrutiny isn’t limited to the Model 3, either. In September, the agency opened a preliminary evaluation into roughly 174,000 Model Y vehicles following reports of electronic door handle failures. Shortly after, Tesla’s design chief, Franz von Holzhausen, acknowledged the regulatory pressure, saying the company is working on an overhaul that would combine electronic and manual door-release mechanisms into a single, more intuitive control inside the cabin.
Tesla’s distinctive flush handles and minimalist interiors have drawn attention before. In 2022, South Korean authorities investigated complaints that Tesla’s concealed door handles could pose safety risks, though that case was ultimately dropped.
For now, Model 3 owners aren’t being asked to take any action. But the investigation underscores a recurring tension for Tesla: balancing sleek, unconventional design choices with clarity and usability in real-world emergency situations.
