The National Highway Traffic Safety Administration opened a formal investigation on December 23, 2025, after receiving a petition in late November that raised concerns about the emergency door‑release mechanism on 2022 Model 3 vehicles. The probe covers 179,071 cars and focuses on a defect that could prevent the door from opening when the battery is depleted or power is lost, creating a potential entrapment risk for occupants.
The defect involves a hidden, unlabeled emergency release that may fail in low‑voltage or power‑loss scenarios. A notable incident that prompted the petition involved Kevin Clouse, a Tesla owner in Georgia, who reported being trapped in a burning Model 3 after a crash. The case illustrates how the mechanism’s lack of intuitive, mechanical backup can lead to dangerous situations.
This investigation follows a broader safety context: at least 15 deaths over the past decade have been linked to Tesla door malfunctions after crashes, and a preliminary evaluation of 174,290 Model Y cars was opened in September 2025 over similar electronic door‑handle failures. The pattern has also fueled lawsuits and heightened scrutiny of Tesla’s design choices.
Tesla’s design philosophy has emphasized a futuristic, minimalist aesthetic, with Elon Musk prioritizing electronic door latches that “look cool.” Engineers have raised safety concerns about the lack of a mechanical release, and the company has stated it is working on redesigning the door handles. Tesla’s safety page now notes that door handles will automatically unlock in the event of a collision, but the new design has yet to be rolled out.
Market reaction to the announcement was muted but measurable: Tesla shares fell 1.4% to $479.01 on the day of the announcement, reflecting investor concern about potential recall costs, regulatory scrutiny, and reputational damage. The dip underscores the market’s sensitivity to safety‑related regulatory actions.
The investigation could lead to a mandatory recall, safety‑related fines, and increased scrutiny of Tesla’s design and testing processes. A recall of 179,000 vehicles would be costly and could erode consumer confidence, while the regulatory action may prompt Tesla to accelerate its door‑handle redesign and invest in additional safety features. The event signals a significant risk to Tesla’s brand and could influence future sales and investor sentiment.
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