Tesla is once again under regulatory scrutiny in the United States, this time over the design and accessibility of emergency door releases in certain Model 3 sedans. Federal safety officials have opened a new defect petition review after claims that the manual door release system may be difficult to locate and operate during emergencies.
The investigation was initiated by the National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation (ODI) on December 23, following a petition filed by Georgia-based Tesla owner Kevin Clouse. The petition asks regulators to formally investigate whether the mechanical door release in model year 2022 Tesla Model 3 vehicles poses a safety risk.
According to NHTSA’s Office of Defects Investigation, the review is evaluating allegations that the mechanical release “is hidden, unlabeled, and not intuitive to locate during an emergency.” The petition covers an estimated 179,071 Model 3 vehicles built for the 2022 model year. At this stage, regulators have not decided whether to grant or deny the request for a full defect investigation.
Clouse’s petition stems from a 2023 incident in which he says he became trapped inside his Model 3 following a crash. In his complaint to NHTSA, he described having to force his way out through a rear window as the interior filled with smoke.
“I was unaware of the location of the hidden mechanical emergency door release because it is not visibly labeled, not explained upon delivery, and not intuitive in an emergency,” Clouse wrote. “I was forced to climb to the back seat and break the rear passenger window with my legs to escape while the interior was burning.” (via Bloomberg)
NHTSA documents indicate at least one reported injury linked to the issue, though no fatalities have been recorded in this specific petition.
This is not the first time Tesla’s door systems have drawn federal attention. In September, NHTSA opened a separate investigation into approximately 174,000 2021 Model Y vehicles after reports that parents were unable to open electric doors for their children when the 12-volt battery failed. Investigators noted that while manual releases exist, children may not be able to access or operate them in an emergency.
Following the news of that investigation, Tesla’s chief designer Franz von Holzhausen announced the company was planning a redesign of its door handles.
You can read the ODI Resume below.
