The National Highway Traffic Safety Administration (NHTSA) has launched an investigation into Tesla Model 3 sedans over concerns regarding the accessibility of emergency door release controls in the vehicles. The probe, covering approximately 179,071 Model 3 vehicles from the 2022 model year, was initiated on December 23, following a defect petition that raised alarms about the hidden and unlabeled nature of the mechanical door release in the Model 3.
Safety experts have long voiced worries that the manual door release in Tesla vehicles may not be clearly visible or marked, especially for rear-seat passengers. This issue has come to the forefront with the NHTSA investigation, as the agency seeks to determine if there is a safety-related defect that needs to be addressed.
Interestingly, Tesla vehicles produced at the company’s Chinese Gigafactory in Shanghai since February 2025 have clear emergency door handle markings on the mechanical release, highlighting a potential difference in design standards between different production locations.
While the opening of a defect petition does not automatically lead to a recall, it signifies the beginning of a regulatory review process that could result in further action if a safety-related defect is identified. This investigation adds to a series of legal and regulatory challenges faced by Tesla related to door design issues, including a recent lawsuit over a fatal crash involving a Model S in Wisconsin.
In response to previous regulatory scrutiny, Tesla’s design chief, Franz von Holzhausen, has acknowledged the need for an overhaul of the door release mechanisms in Tesla vehicles to make them more intuitive and user-friendly in emergency situations. This move follows a preliminary evaluation by the NHTSA into electronic door handle failures in approximately 174,000 Model Y vehicles.
Tesla’s unique design choices, including flush door handles and minimalist interiors, have garnered attention in the past, with authorities in South Korea previously investigating complaints about the safety risks posed by Tesla’s concealed door handles.
For now, Model 3 owners are not required to take any immediate action, but the ongoing investigation highlights the challenge faced by Tesla in balancing innovative design features with the need for clarity and usability in real-world emergency scenarios. As Tesla navigates these regulatory challenges, it remains to be seen how the company will address concerns raised about the accessibility of emergency door releases in its vehicles.