Tesla Recalls Nearly Three Million Cars in China Over Hidden Door Handles

Tesla is recalling nearly three million cars in China because of safety concerns over hidden door handles that may fail to open during emergencies.

The recall, announced by China's State Administration for Market Regulation, affects Model S sedans sold since 2014 and is part of the country's largest-ever vehicle recall, impacting over four million cars.

Hidden door handles, popularized by Tesla and other EV makers for their sleek design and reduced wind drag, have been linked to difficulties in opening doors during emergencies.

Around 60% of China's top 100 best-selling new energy vehicles use this design, according to industry analyst Stephen Dyer of AlixPartners.

Critics say the handles pose safety risks, as doors may not open promptly after crashes or electrical failures, delaying rescue efforts.

Nanyang Technological University associate professor Lyu Chen noted that door handles become safety-critical in the seconds after a crash.

Xiaomi faced scrutiny in 2025 after two fatal crashes involving its SU7 model, where occupants were trapped due to door issues.

One incident in Tongling city killed three people, with reports stating passengers could not unlock doors after the collision.

Xiaomi stated its SU7 models include mechanical emergency release handles at the bottom of each door that work without power.

Tesla has been sued in the U.S. over similar door handle concerns, including a 2024 Cybertruck crash in California that killed three students.

Survivor Jordan Miller alleged that the Cybertruck's lack of mechanical door handles trapped passengers in the burning vehicle.

Tesla denies wrongdoing, stating the Cybertruck complies with U.S. federal safety standards.

Other U.S. cases involve passengers, including children, reportedly trapped in Tesla vehicles due to door malfunctions.

In February, China mandated a ban on hidden door handles, requiring physical release mechanisms on both inside and outside of doors.

The new rules, effective January 1, 2027, prohibit selling new cars without physical door release mechanisms.

Car interiors must also display signs showing how to open doors manually.

China's regulation marks the first country to ban hidden door handles, with the U.S. and EU currently reviewing similar safety concerns.

Tesla and Chinese automakers Xiaomi, XPeng, and Geely are recalling over four million vehicles to add warning labels and software updates that lower windows during crashes.

Tesla is recalling nearly three million cars because handles are hard to identify due to matching interior trim colors.

The agency warned that in electrical failures, handle design may hinder escape or rescue efforts.

Xiaomi, XPeng, and Geely will recall over 750,000 vehicles for similar updates.

Some engineers argue the measures are insufficient, as they do not ensure mechanical door access during emergencies.

National University of Singapore instructor Lim Hong Wee said emergency access should not depend on software.

SecureSafe risk manager Gokul Krithivasan called warning labels a 'weak remedy' since panic impairs reading ability in smoke-filled cabins.

It remains unclear if similar recalls will occur outside China.

The U.S. National Highway Traffic Safety Administration is reviewing whether to require emergency door-exit systems.

European regulators have drafted new standards to ensure hidden handles function without power.

Lyu Chen noted that while hidden handles are common in EVs, manufacturers and regulators are increasingly focused on door safety.

Global carmakers are adapting to China's market, where safety rules may influence international standards.

The common principle, he said, is that emergency entry and exit must remain possible even after power loss.