Tesla is facing one of its biggest safety challenges in the Chinese market, as it is being forced to recall 2,975,910 vehicles due to a problem with the emergency door release mechanism . The Chinese market regulator found that the solution is difficult to detect and use in emergency conditions , especially after a serious collision.
The development is Tesla's largest recall in China to date and is of particular significance as the company's door design is already under increased scrutiny from regulators and courts in different markets.
Nearly 3 million Teslas in the crosshairs
According to data filed with the State Administration for Market Regulation (SAMR), the recall involves 973,156 Model 3s and 1,956,713 Model Ys manufactured in China. It also includes 35,590 imported Model 3s, 8,328 Model Xs and 2,123 Model Ss.
See also: Tesla recalls cheaper Cybertruck due to possible wheel detachment
The problem isn't with Tesla's signature recessed exterior door handles, but with the internal mechanical mechanism that acts as a backup solution. This is the system that allows passengers to manually open the door when the car's electrical system has been disabled.
Why is it considered a security problem?
SAMR found that this mechanism is not easily distinguished from the rest of the interior trim, as it has a similar color scheme. Under normal circumstances, this may seem like a purely design detail. However, in a car accident, it can become critically important.
In the event of a power failure, automatic door functions may not be available. A passenger who is panicking, injured, or without adequate interior lighting may have difficulty quickly identifying and operating the mechanism.
This highlights a broader issue for the modern automotive industry: as more functions are transferred from traditional mechanical switches to electronic systems, the more important it becomes to have clear and easily accessible backup solutions.
Tesla's solution without changing hardware
Tesla is not replacing the mechanism. Instead, the recall plan includes placing warning labelsto make the mechanism easier to spot, as well as an over-the-air software update.
The OTA update will modify the way the windows roll down, making it easier for passengers to exit in an emergency. The recall process is set to begin on September 25, 2026.
The choice of software instead of mechanical modification also shows how differently security issues are now being addressed in so-called "software-defined vehicles", where even functions related to physical access to the vehicle can be affected by software updates.
See also: Tesla recalls 10% of Cybertrucks due to faulty adhesive
Recall from other manufacturers as well
Tesla is not the only company facing this issue in China. On the same day, eight other manufacturers filed recalls with SAMR for problems related to the internal door opening mechanism.
The list includes Xiaomi, Leapmotor, Xpeng, Geely, Chery, Dongfeng, BAIC BluePark and FAW. The development highlights that the issue is not limited to one manufacturer, but is linked to a broader trend in electric and modern car design.
However, the size of Tesla's recall stands out significantly, with nearly three million vehicles affected.
China tightens rules
The decision comes after China tightened its regulations on recessed handles. In February, Chinese authorities finalized restrictions on this type of design, citing safety concerns.
The development shows that authorities are now looking not only at the performance and efficiency of electric vehicles, but also at how passengers can abandon a car when electronic systems fail.
See also: Tesla recalls 63,619 Cybertrucks due to parking light issue
Pressure also in the United States
Meanwhile, Tesla's door design is under increased scrutiny in the US. The company is facing lawsuits linking the door mechanisms to incidents of passenger entrapment after crashes.
NHTSA has also examined the issue, and in July it rejected a request for a formal defect finding, but that did not end the debate over safety regulations . At the same time, the SAFE Exit Act has been proposed in Congress , aiming to change the specifications governing vehicle exit mechanisms.
The Tesla case ultimately shows that the design of a car is no longer evaluated solely on the basis of aesthetics or aerodynamics. In an era where vehicles are increasingly dependent on electronic systems and software, the ability of the passenger to quickly and intuitively exit the car at a critical moment is an equally important safety element.
