Tesla is redesigning its electronic door handles after regulators started investigating safety problems. This decision follows reports that people, including kids, got stuck inside Tesla cars when the door system stopped working. Some cases led to serious injuries or deaths.
Tesla’s safety troubles sparked a regulatory investigation. According to a Bloomberg report, 140 people were trapped inside Teslas because of faulty handles. The National Highway Traffic Safety Administration (NHTSA) began looking at over 174,000 Model Y vehicles from 2021 after parents broke windows to reach their children. The existing system uses a 12-volt battery for the handles. If the battery does not work or has low voltage, getting into the car from outside is impossible. NHTSA confirmed that in four cases, adults had to smash windows to help children.
Tesla’s planned redesign
Franz von Holzhausen, Tesla’s design chief, says the company is building a new button that merges the electronic and manual door release. Right now, the releases are in separate, hidden spots. The plan is to help people act faster if there is an emergency. Von Holzhausen told Bloomberg, “The idea of combining the electronic one and the manual one together into one button, I think, makes a lot of sense. That’s something that we’re working on.” The new handle will be easier to use in panic situations.
Tesla is testing changes in China. Chinese authorities may soon ban all fully hidden electronic door handles by July 2027, citing safety risks. New rules could force carmakers to add mechanical backups, keeping semi-retractable or classic handle options. Tesla is watching these moves closely. Von Holzhausen said they’re working on a solution for the evolving rules.
Serious incidents highlight risks
This isn’t the first time door handles have caused problems for Tesla. Since 2018, NHTSA has logged more than 140 complaints from owners across models like the Model S, Model 3, Model Y, and Cybertruck. Problems included doors that would not open or got stuck. There have been some severe incidents. For example, an off-duty firefighter was burned trying to rescue someone from a burning Model Y. Some students lost their lives trapped in a Cybertruck during a fire. Alijah Arenas, a USC basketball player, had to kick out his Cybertruck’s window to get out after it caught fire. He spent time in a medically induced coma because of smoke.
Retrofitting older Teslas is not expected. The new button may only be available on future cars. The manual release location varies between models and can be hard to find. For instance, the Model S has a release cable hidden under the rear seat carpet. Some Model 3 and Model Y vehicles produced before 2024 do not have manual rear door releases at all.
NHTSA officials say the initial investigation may grow. They plan to check how Tesla powers the door locks and the reliability of those systems. Consumer advocates welcome the attention. Rosemary Shahan, who leads an auto safety group, said, “It’s good to see that NHTSA is probing this serious issue. No one should have to resort to breaking the windows to get into their own car when their child or pet is trapped inside because the door handles fail to work”.
Tesla has not said when the new door handle update will appear or what models get it first.
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