US Safety Regulator Probes Tesla Model 3 Emergency Door Release Design

The National Highway Traffic Safety Administration (NHTSA) in the USA has launched an official investigation into the emergency door release mechanisms in the Tesla Model 3, covering approximately 180,000 vehicles. The probe centres on allegations that the manual door releases are difficult to locate during emergencies, potentially delaying escape or rescue efforts following crashes.

The investigation, designated as Defect Petition DP25002, focuses on Model Year 2022 Tesla Model 3 vehicles, with an estimated 179,071 units affected. According to documents released by the Office of Defects Investigation (ODI), the evaluation was prompted by a petition claiming that "the mechanical door release is hidden, unlabelled, and not intuitive to locate during an emergency."

While Tesla's electronic door handles are a signature design feature, they require electrical power to operate. In severe crashes where power is lost, occupants or first responders must use mechanical overrides. The petition alleges these overrides are not sufficiently obvious, potentially hindering emergency egress.

The investigation comes amid several media reports of fatal crashes where occupants or rescuers reportedly struggled to open doors. Bloomberg and other outlets have identified multiple incidents where door handle design may have played a role in fatalities. The ODI has so far associated one injury incident with this petition.

Tesla owners familiar with the Model 3 note that the front manual release is located right in front of the window switches, so obvious that passengers sometimes pull it by mistake. However, the rear releases are considerably more complex. Users must locate a small cover at the bottom of the door pocket, remove it with a finger, and then pull a hidden loop inside.

While these steps can be performed quickly if known, critics argue most people would struggle to discover the method during an emergency, especially passengers unfamiliar with the vehicle.

The investigation is currently in the "Defect Petition" phase, where the agency will evaluate whether to grant or deny the petition. If the NHTSA determines the design delays emergency egress, potential remedies could range from adding clear labels to the release locations to retrofitting more obvious physical levers.

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