Federal Regulators Launch Safety Probe into Tesla Model 3 and Y Door Handle Failures

In a move that sends ripples through the electric vehicle industry, federal safety regulators have launched a significant investigation into Tesla's Model 3 and Model Y vehicles, focusing on a critical safety feature: the door handles. The National Highway Traffic Safety Administration (NHTSA) announced a preliminary evaluation into an estimated half-million Tesla vehicles after receiving a disturbing number of complaints about occupants being unable to exit their cars, particularly in emergency situations.

The core of the issue lies with the manual override mechanism for the doors.

Owners of 2018-2023 Model 3 and 2020-2023 Model Y vehicles have reported instances where, after a crash, the doors failed to open, trapping occupants inside. The situation is not only terrifying for those involved but also poses a severe challenge for first responders attempting to extract people from damaged vehicles.

NHTSA has received 124 complaints regarding this issue, with 54 specifically citing an inability to exit after a crash and six even mentioning "non-crash thermal events," suggesting fire or other heat-related incidents.

This isn't the first time Tesla has faced such scrutiny. NHTSA previously investigated similar door handle issues in older Model S and Model X vehicles (from model years 2014-2016).

That probe ultimately led to a recall of 120,000 Model S vehicles, where the door handles could fail to deploy in crashes. For Model X, Tesla provided an over-the-air software update to address the concerns. The current investigation suggests that the problem, or a variation of it, may persist in newer models.

Tesla, for its part, has already taken steps to address the design flaw.

The company reportedly implemented a mechanical release lever in Model 3 vehicles manufactured after October 2021 and Model Y vehicles produced after November 2021. This redesign aimed to provide a more reliable means of egress. However, NHTSA's preliminary evaluation will now determine whether this updated design fully mitigates the safety risk and, crucially, if a recall is necessary for the hundreds of thousands of older Model 3 and Model Y vehicles still on the road that lack this mechanical failsafe.

The outcome of this investigation could have significant implications for Tesla, potentially leading to a massive recall campaign.

Beyond the financial cost, such a recall could dent consumer confidence and further highlight the challenges of balancing innovative design with fundamental safety requirements. As the investigation progresses, all eyes will be on NHTSA's findings and Tesla's response to ensure that occupants can always safely exit their vehicles, especially when seconds count.