Tesla faces widening federal probe into door handle safety issues

Tesla is currently facing an escalating federal investigation over potential safety issues related to its flush-mounted, retractable door handles. The National Highway Traffic Safety Administration (NHTSA) has mandated that the automaker submit relevant records as part of this in-depth inquiry. This action comes in response to numerous complaints from Tesla owners, who reported difficulties entering and exiting their vehicles due to battery failures and other complications affecting the functionality of the door handles. Some alarming cases have emerged where children found themselves trapped inside hot vehicles, necessitating urgent interventions from first responders or even window breakage to free them. As of October 27, 2025, NHTSA's Office of Defects Investigations has documented 16 instances of door handles failing to operate due to low 12VDC battery voltage in specific 2021 Model Y vehicles. The investigation was prompted by a Bloomberg report that highlighted serious incidents involving individuals becoming trapped in their Teslas following collisions or power outages that hindered the normal operation of the doors. In light of these issues, Tesla’s design leader, Franz Von Holzhausen, has indicated that the company plans to revise the design of its door handles. Competitors in the industry are taking note as well; Rivian is reconsidering similar door handle designs, while Volkswagen's CEO, Thomas Schäfer, noted that their customers prefer traditional door handles and have no intentions of adopting electronic designs. Additionally, China is moving towards new vehicle safety regulations that will require more user-friendly emergency door release mechanisms. The NHTSA's probe is extensive, targeting all 2021 Tesla Model Y vehicles sold or leased in the U.S., along with comparable models from 2017 to 2022. Tesla has until December 10 to comply with NHTSA's request for information, which encompasses door handle systems, door latches, software, and related components. Failure to respond accurately or promptly could result in substantial fines, potentially exceeding $139 million, as outlined by NHTSA.