NHTSA Launches Investigation into Tesla’s Emergency Door-Release System
The National Highway Traffic Safety Administration (NHTSA) has opened a defect investigation into roughly 179,000 Tesla Model 3 vehicles to evaluate reports that the emergency door-release mechanism may not function properly.
The National Highway Traffic Safety Administration (NHTSA) has opened a defect investigation into roughly 179,071 2022 Tesla Model 3 vehicles over concerns that the emergency door release may be difficult to locate or operate during an emergency.
The probe, initiated by NHTSA’s Office of Defects Investigation on December 23, 2025, currently focuses on that model year but could expand to other Model 3 years and the Model Y, which uses the same interior and exterior door-handle designs. The inquiry was prompted by consumer complaints describing the mechanical emergency release as “hidden, unlabelled, and not intuitive to locate during an emergency.”
The filing cites a 2023 incident in Georgia involving Kevin Clouse, who became trapped in a burning vehicle after an electrical failure disabled normal exits. Unable to find the emergency release, he had to kick out a rear passenger window to escape and sustained a broken hip and arm.
This is a preliminary evaluation rather than a recall. However, if the NHTSA determines that a safety-related defect exists in Tesla’s door-release design, the investigation could lead to further regulatory action.
The investigation reflects growing scrutiny of Tesla’s reliance on electronic door latches and the accessibility of their mechanical backups. In November 2024, the family of two people killed in a Model S crash sued Tesla, alleging the electronic door release failed after the battery pack was damaged and occupants were trapped. Similar lawsuits followed a Cybertruck crash that month, with plaintiffs saying victims were unable to exit because of door-handle design.
Pressure on Tesla is not limited to the United States. China has proposed rules requiring both interior and exterior electronic handles to include clearly visible, easy-to-find mechanical releases on both sides of the door.
Tesla appears to be addressing these concerns. In a September interview, design chief Franz von Holzhausen acknowledged the problem and said the company is working to combine manual and electronic door releases into a single interface designed to meet regulatory safety requirements worldwide, including in the U.S. and China.
The probe, initiated by NHTSA’s Office of Defects Investigation on December 23, 2025, currently focuses on that model year but could expand to other Model 3 years and the Model Y, which uses the same interior and exterior door-handle designs. The inquiry was prompted by consumer complaints describing the mechanical emergency release as “hidden, unlabelled, and not intuitive to locate during an emergency.”
The filing cites a 2023 incident in Georgia involving Kevin Clouse, who became trapped in a burning vehicle after an electrical failure disabled normal exits. Unable to find the emergency release, he had to kick out a rear passenger window to escape and sustained a broken hip and arm.
This is a preliminary evaluation rather than a recall. However, if the NHTSA determines that a safety-related defect exists in Tesla’s door-release design, the investigation could lead to further regulatory action.
The investigation reflects growing scrutiny of Tesla’s reliance on electronic door latches and the accessibility of their mechanical backups. In November 2024, the family of two people killed in a Model S crash sued Tesla, alleging the electronic door release failed after the battery pack was damaged and occupants were trapped. Similar lawsuits followed a Cybertruck crash that month, with plaintiffs saying victims were unable to exit because of door-handle design.
Pressure on Tesla is not limited to the United States. China has proposed rules requiring both interior and exterior electronic handles to include clearly visible, easy-to-find mechanical releases on both sides of the door.
Tesla appears to be addressing these concerns. In a September interview, design chief Franz von Holzhausen acknowledged the problem and said the company is working to combine manual and electronic door releases into a single interface designed to meet regulatory safety requirements worldwide, including in the U.S. and China.
