Tesla's new trouble: US regulators investigate Model 3 emergency door release mechanism

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Tesla is facing a new round of investigation by the U.S. federal vehicle safety regulator. This regulatory action targets the Model 3 sedan’s emergency door release mechanism, questioning whether it is sufficiently prominent and easy to use in emergencies.

The National Highway Traffic Safety Administration (NHTSA) announced on Wednesday, 24th Eastern Time, that it has launched a defect investigation into about 179,000 units of the 2022 Model 3. The investigation was prompted by a petition filed by owner Kevin Clouse, who claimed he was trapped inside a burning Tesla in 2023 and ultimately had to kick out the rear seat window to escape.

NHTSA stated it is evaluating allegations that the “mechanical emergency door handle is hidden, unmarked, and hard to locate in emergencies.” The agency has not yet decided whether to approve this defect petition for further investigation.

Both Tesla and NHTSA have not responded to media requests for comment. Commentators pointed out that the launch of a defect investigation by regulators does not equate to a recall but marks the start of regulatory review. If a safety-related defect is confirmed, further regulatory action may result.

This investigation broadens the scope of federal scrutiny over Tesla’s door issues. In September this year, NHTSA launched a separate probe into a door defect in the Model Y involving about 174,000 vehicles, focusing on reports of children being trapped inside when the 12V battery fails. Model 3 and Model Y are Tesla’s top-selling models.

On the day NHTSA announced the investigation, Tesla’s stock price fell at the beginning of trading, hitting a daily low with an intraday drop of 1.8%, before recovering most of the loss to close down slightly by 0.03%. After approaching a record closing high on Monday, Tesla shares fell for a second consecutive day against the broader market.

Owner’s Petition Triggers Investigation

Kevin Clouse, a Tesla owner from Georgia, detailed his 2023 ordeal in a petition submitted last month. In a complaint filed with NHTSA, he said: “I did not know the location of the hidden mechanical emergency door release, as it was not clearly marked, nor explained at delivery, and was not intuitive in an emergency.”

Clouse recounted his dangerous experience due to vehicle issues: “The car was burning inside at the time, and I was forced to crawl to the back seat and use my legs to break out of the rear passenger window to escape.”

NHTSA’s Office of Defects Investigation (ODI) stated in its filing that the focus is on “whether the emergency exit control device is easily accessible and clearly identifiable.”

The case is currently related to one injury incident. NHTSA emphasized it is at the “defect petition” stage and will “evaluate the issue and decide whether to grant or deny the petition.”

Electric Door Handle Design Continues to Draw Controversy; Multiple Fatal Accidents Have Occurred

Tesla is a pioneer in electric door handles, but this power-dependent design can suddenly fail in the event of a power outage, especially after a collision. Although Tesla vehicles are equipped with mechanical emergency releases to address power loss, experts have long argued that these manual devices lack visibility, clear markings, and intuitiveness—especially for rear seat passengers.

There were previous reports that during Model 3’s development, someone raised safety concerns to CEO Elon Musk regarding electric door handles, but Musk insisted on this futuristic design and added a manual unlocking feature to address power failure risks.

According to a media analysis published this week, at least 15 people have died in more than ten accidents over the past decade where occupants or rescuers were unable to open Tesla doors that had been damaged and caught fire.

Last month, Tesla was sued over a fatal accident in Wisconsin. In that case, all five occupants of a Model S died, and the lawsuit claims that a design defect trapped them inside, unable to open the luxury sedan’s doors.

In November last year, two college students died in a Cybertruck crash in the suburbs of San Francisco. Their families also sued Tesla, claiming the two were trapped in the burning vehicle due to the door handle design.

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