Tesla and eight other automakers announced on Friday they are recalling approximately 4.3 million vehicles in China due to concerns that electronic door handles may be difficult to open during emergencies. The recall involves popular electric vehicle manufacturers including Xiaomi, Leapmotor, Xpeng, and Geely, marking the largest-ever vehicle recall in China. The companies issued software updates on Friday to address the issue, which centers on handles that sit flush with the car body and extend electronically when the owner approaches.
Electronic door handles have become common on electric vehicles (EVs) over the last decade to improve aerodynamics and provide a minimalist appearance. However, Michael Brooks, executive director of the Center for Auto Safety, stated that these systems often use buttons rather than traditional mechanical levers. Brooks noted that if a car loses power and lacks a clear manual release, occupants may struggle to exit during life-threatening situations. He specifically cited Tesla’s manual release placement in door pockets or under panels without clear signage as a potential hazard.
Automakers have faced increasing scrutiny over these designs following reports of difficulty during emergencies. Several lawsuits have alleged that Tesla's handle designs led to injuries or deaths after individuals became trapped in burning vehicles. Additionally, some drivers have filed complaints with the U.S. National Highway Traffic Safety Administration (NHTSA) regarding inability to extract children from vehicles. A 2023 study by JD Power found that door handles are a growing problem area for consumers, with EVs accounting for seven of the ten most problematic models in this category.
The financial and regulatory scale is significant, as China has already announced it will ban "hidden" door handles starting in 2027. This sets a precedent that could force global manufacturers to redesign their vehicle lineups. In the United States, proposed legislation would require all cars with electronic handles to include a fail-safe manual release. The NHTSA is currently considering the creation of a new formal safety standard for all automakers after reviewing a petition regarding Tesla Model 3 sedans. While the agency denied a specific recall petition in July, it opted to pursue broader rulemaking that would affect all manufacturers selling cars in the U.S.
The knock-on effects could lead to a divergence in safety standards between international markets. Michael Brooks of the Center for Auto Safety noted that a recall in China does not guarantee a similar move in the U.S. or Europe, suggesting Tesla might contest such requirements in the American market. For now, the United Nations Economic Commission for Europe is drafting standards to ensure handles can be opened from both sides if power is lost. Owners of affected vehicles in China began receiving software updates on Friday, while regulators in the U.S. and Europe have not yet announced specific deadlines for new mandatory design changes.