NHTSA Opens Review of Tesla Model 3 Emergency Door Release Design

NHTSA has opened a defect petition to review Tesla Model 3 emergency door releases after reports raised safety concerns. Read what the agency is examining.

The U.S. National Highway Traffic Safety Administration (NHTSA) has opened a defect petition review into the 2022 model year Tesla Model 3, focusing on concerns about the design of the vehicle’s emergency mechanical door releases.

The review covers an estimated 179,000 vehicles and follows complaints claiming that the manual door release mechanisms are difficult to locate and identify during emergencies. According to NHTSA, the process is still at an early stage, and opening a defect petition does not automatically mean a recall or a confirmed safety defect.

The core issue centers on situations in which a serious crash causes a total loss of electrical power. In such cases, Tesla’s electronic door-opening systems may not function, leaving occupants and first responders dependent on mechanical overrides. The petition argues that these manual releases are hidden, unlabeled, and not intuitive, potentially delaying escape or rescue.

In its description of the case, NHTSA states that the subject of the review is whether emergency egress controls are “readily accessible and clearly identifiable.” At this point, the agency has linked one injury incident to the petition, but the scrutiny comes amid broader media investigations.

Reports by Bloomberg and The Washington Post have highlighted several fatal crashes involving Tesla vehicles in which door handle design and power-dependent opening systems may have complicated rescue efforts. Some of those cases involved passengers or rescuers struggling to open doors after electrical systems failed.

Tesla’s minimalist door design has long been a signature feature, prioritizing clean aesthetics and aerodynamics over traditional mechanical handles. That design philosophy is now drawing regulatory attention. If NHTSA ultimately determines that the layout of the emergency releases slows evacuation, the review could lead to further action, ranging from clearer labeling to more substantial design changes. For now, however, the agency is only beginning its evaluation, and the outcome remains uncertain.