China Recalls More Than 4 Million Vehicles Over Hidden Door Handle Safety Concerns
China has launched its largest vehicle recall to date, affecting more than four million cars over concerns that increasingly popular hidden door handles could make it difficult for occupants to escape during emergencies.
The recall covers about 2.98 million Tesla vehicles manufactured in China, including selected Model 3, Model Y, Model S and Model X units. Chinese automakers XPeng, Xiaomi and Geely are also affected.
The safety action focuses on electronic door handles that can be difficult to identify or operate, particularly when a vehicle loses electrical power following a serious collision.
Tesla said some of its vehicles have handles that blend into the surrounding interior trim, potentially making them harder to locate. The company warned that if a severe crash causes the low-voltage electrical system to fail, occupants could struggle to open the doors quickly, while rescuers outside the vehicle could also face difficulties accessing the cabin.
As part of the recall, affected Tesla vehicles will receive warning labels explaining how to operate the doors in an emergency. The company will also introduce a software update designed to automatically lower the vehicle’s windows following a collision.
Concerns over hidden handles have intensified in China following two fatal crashes involving Xiaomi electric vehicles. Power failures were suspected of contributing to difficulties opening the vehicles’ doors, although the circumstances surrounding those incidents have prompted broader scrutiny of the design.
The minimalist handles became increasingly common among electric vehicle manufacturers after Tesla popularised the styling on its Model S. According to Tu Le, managing director of consultancy Sino Auto Insights, Chinese automakers subsequently adopted the design as it became associated with a sleek, modern appearance.
However, Le described the latest recall measures as more of a temporary fix than a permanent solution.
Chinese authorities have already moved to address the issue through regulation. In February, officials announced new rules banning fully hidden door-handle designs. From January 1, 2027, vehicles sold in China will be required to have a mechanical emergency release accessible from both inside and outside the vehicle.
The issue has also attracted attention in the United States. Tesla’s door handles have previously been examined by US safety regulators following reports of failures that allegedly left children trapped inside vehicles.
In July, the US National Highway Traffic Safety Administration proposed developing a formal safety standard covering emergency vehicle exits. The agency is currently assessing whether manufacturers should be required to provide specific emergency door-release systems.
The latest Chinese recall highlights a growing safety debate surrounding vehicle design, as manufacturers balance minimalist styling and advanced technology with the need for reliable emergency escape systems.
