US Opens Defect Investigation Into Tesla Model 3 Door Releases

The US auto safety regulator announced on Wednesday that it has opened a defect investigation into Tesla Model 3 compact sedans over concerns that emergency door release controls may not be easily accessible or clearly identifiable during an emergency.

The Office of Defects Investigation said the probe covers an estimated 179,071 Model 3 vehicles from the 2022 model year. The investigation, which began on December 23, follows a defect petition claiming that the vehicles’ mechanical door releases are hidden, unlabeled, and not intuitive to locate in urgent situations.

Tesla did not immediately respond to a request for comment.

Tesla vehicles rely primarily on electronic door latches that open via buttons instead of traditional mechanical handles. While the company provides a manual door release for emergencies or power failures, safety experts have long argued that these mechanical releases are not consistently visible, clearly labeled, or easy for passengers—especially those in the rear seats—to operate under stress.

The investigation comes amid a series of lawsuits involving Tesla’s door design. Last month, the company was sued over a fiery crash in Wisconsin that killed all five occupants of a Model S. The lawsuit alleges that a design flaw prevented the passengers from opening the sedan’s doors.

Tesla has also faced legal action from families of two college students killed in a Cybertruck crash in November last year in a San Francisco suburb. The families claimed the door handle design trapped the students inside the burning vehicle.

The opening of a defect petition does not automatically trigger a recall but marks the first step in a regulatory review that could lead to further action if the National Highway Traffic Safety Administration (NHTSA) determines a safety-related defect exists.

NHTSA has been monitoring Tesla’s door mechanisms closely. In September, the agency launched a preliminary evaluation into approximately 174,290 Model Y cars following reports that their electronic door handles could become inoperative.

Industry analysts say the investigations highlight ongoing safety concerns related to Tesla’s reliance on electronic systems for basic vehicle functions. While electronic handles and automated features are marketed for convenience and modern design, critics argue that mechanical backups must remain intuitive and clearly accessible to prevent entrapment during emergencies.

The investigation into the Model 3 will examine whether Tesla’s manual releases meet regulatory requirements and provide passengers with reliable emergency egress. NHTSA will review the design, placement, labeling, and accessibility of these controls before deciding whether additional action, including a potential recall, is necessary.

The Model 3 is one of Tesla’s most popular vehicles, and the outcome of the probe could have wide-ranging implications for the automaker, particularly as the company continues to expand its fleet of fully electric vehicles worldwide.