Tesla to recall millions of cars in China over deadly flush door handles
Tesla will recall three million vehicles from the Chinese market because its flush-mounted door handles can jam shut after severe crashes, trapping occupants. China has become the first country to ban such handles outright starting in 2027.
US electric carmaker Tesla is recalling three million vehicles from the Chinese market after finding that its signature flush-mounted door handles can turn deadly in serious crashes, British broadcaster BBC reports.
When a car loses electrical power in a severe collision, for instance if the 12-volt battery is damaged, the electronic door locks stop working and the handles remain retracted into the body, making them impossible to open. Germany has already recorded several fatal incidents in which people burned to death inside Tesla vehicles after the automatic emergency door-release system failed to activate. Backup mechanical handles inside the cabin are often hard to notice because they are colored to match the interior trim.
Why China moved first
China, now a global hub for electric vehicles, has seen fierce competition, with local manufacturers such as Xiaomi, Geely and XPeng widely copying Tesla's flush handle design. After several fatal crashes, including ones involving Xiaomi electric cars, authorities decided to act. The total number of vehicles recalled in China, including models from other manufacturers, has already reached 4.3 million. From January 1, 2027, China will ban the sale of cars with electronic handles lacking a mechanical safety backup — all new vehicles must have physical handles, inside and out, that work even without electricity.
Temporary fixes for cars already on the road
Since millions of already-produced cars cannot be physically rebuilt, manufacturers are offering interim solutions. Bright warning stickers will be placed near doors inside cabins, pointing to the location of the emergency mechanical release. Additionally, cars will receive an over-the-air software update that automatically lowers the side windows once sensors detect a severe collision, allowing occupants to climb out or rescuers to reach them from outside.
The US National Highway Traffic Safety Administration is already investigating reports of Tesla door handles suddenly failing, and in July regulators proposed a new federal safety standard requiring all manufacturers to install obvious mechanical emergency door-release systems. Similar discussions have begun within EU safety bodies as well.
