NHTSA Opens Investigation into Tesla’s Emergency Door Release

The National Highway Traffic Safety Administration (NHTSA) has opened a defect investigation into roughly 179,000 Tesla Model 3 vehicles amid concerns that the emergency door release may be hard to find or operate in an emergency.

The Investigation

NHTSA’s Office of Defects Investigation initiated the probe on December 23, 2025, targeting an estimated 179,071 2022 Model 3 vehicles. While the current scope is limited to that model year, the inquiry could expand to other model years and to the Model Y, which uses the same interior and exterior door-handle designs as the Model 3.

According to filings, the investigation began after complaints said the mechanical door release is “hidden, unlabelled, and not intuitive to locate during an emergency.”

The filing cites a 2023 incident in Georgia involving Kevin Clouse. During that event, Clouse became trapped inside his burning vehicle after the electrical system failed; unable to find the emergency release, he kicked out a rear passenger window to escape and suffered a broken hip and arm.

At this stage the inquiry is a preliminary evaluation rather than a formal recall. If NHTSA determines there are safety-related defects in the design, the probe could lead to further regulatory action.

Growing Scrutiny

The investigation follows increasing scrutiny of Tesla’s use of electronic door latches and questions about how accessible the mechanical backups are when electronics fail.

In November, the family of occupants who died in a Model S crash filed a lawsuit alleging the electronic door-release system failed after the battery pack was damaged, trapping people inside. Similar lawsuits were filed after a Cybertruck crash in November 2024, with families claiming victims were trapped because of the door-handle design.

Global Pressure

Regulators outside the United States are also focusing on the issue. China recently proposed new rules addressing both interior and exterior electronic door handles that would require clearly visible, easy-to-find mechanical releases on both sides of the door.

Future Design Changes

Tesla appears to recognize the problem and is exploring design changes. In a September interview, Tesla design chief Franz von Holzhausen acknowledged issues with the current door-handle approach and said the company is looking to combine the manual and electronic door releases into a single interface that would meet safety requirements in regions including the U.S. and China.