The NHTSA has opened an investigation into emergency door mechanisms on about 180,000 2022 Tesla Model 3 vehicles, prompted by a defect petition from an owner trapped in a post-crash fire. This follows a Bloomberg report documenting 15 related deaths and prior scrutiny of Model Y doors.
Building on a Bloomberg investigation that linked 15 deaths over the past decade to Tesla vehicles trapping occupants due to failed electronic doors post-crash, the National Highway Traffic Safety Administration (NHTSA) initiated Defect Petition DP25002 on December 23, 2025. The probe targets approximately 179,071 to 180,000 2022 Model 3 sedans, examining claims that mechanical overrides are hidden, unlabeled, and hard to locate in emergencies.
The petition originated from Kevin Clouse, a Georgia Model 3 owner involved in a head-on collision. After power loss and interior fire, electronic releases failed, forcing Clouse to crawl to the rear and shatter a window by kicking it, resulting in a broken hip, arm injuries, and multiple surgeries. He contends the manual releases violate federal accessibility standards, lacking visible labels or delivery instructions.
Tesla's minimalist electronic handles rely on a 12-volt battery prone to crash failure. Front door releases are in the armrest ahead of window switches, while rear ones can be under rugs, behind grilles, or missing in some variants. Owners report confusion, with some accidentally damaging trim.
This action follows a September 2025 NHTSA review of Model Y doors and over 140 complaints since 2018. Bloomberg noted engineer warnings to Elon Musk during Model 3 development, overruled for design preferences despite added manual backups. Rideshare drivers now brief passengers on escapes, and aftermarket glass breakers are popular.
Tesla Chief Designer Franz von Holzhausen indicated in September 2025 plans for a combined electronic-manual button. In late December, Tesla added a 'Safer Aftermath' website section touting automatic unlocks, hazard lights, and calls post-collision, though rollout details are unclear. Ongoing lawsuits, such as one over a 2024 fatal Cybertruck fire, underscore persistent concerns. NHTSA will assess the petition for potential recalls if egress proves inadequate.