NHTSA Rejects Tesla Door-Release Defect Claim

NHTSA has made its decision on the petition filed by Kevin Clouse about hidden manual door releases in some Tesla Model 3 cars. They denied his request to open an investigation into a possible defect, but at the same time agreed to start writing new rules for emergency door releases across all auto manufacturers.

The denial affects 179,031 of these vehicles from model year 2022. NHTSA found only one complaint that matched Clouse’s allegation - and it was actually filed by him himself. They said there isn’t a federal safety standard yet covering how to label or locate mechanical door releases.

A problem exists with FMVSS 206, which covers door locks, latches, and hinges meant to keep people from getting thrown out of the car in an accident. But this standard doesn’t address what happens when manual releases are hidden or unlabeled, creating a risk that someone might get trapped inside. NHTSA noted that Tesla’s owner’s manuals include illustrations showing where these secret releases can be found - under ‘In Case of Emergency’.

NHTSA decided they don’t think the issues Clouse raised point to any safety problem serious enough for an investigation into defects. Instead, they suggest dealing with it through rulemaking - creating new rules and regulations that would apply across all cars.

A different petition filed in November 2025 asked NHTSA to make a law requiring ‘a robust and obvious door egress system’ in every car on the road. This one was approved, so now NHTSA will start writing formal rules for emergency exits. They emphasized how important it is that people can get out of their cars safely during emergencies.

NHTSA’s decision marks an important development in the ongoing debate about Tesla’s design choice for door releases. A month before this ruling, they started investigating Model Y door handles after parents complained their kids were getting trapped when the power system died and couldn’t open the doors from inside. Days later, Tesla announced it was redesigning its door handles to combine electronic and manual systems.

Tesla is facing a series of deadly lawsuits over its door-handle design, even as they’re sending out software patches in China to fix cars with this problem. Congress introduced the SAFE Exit Act in January, highlighting 15 deaths linked to difficulty accessing door handles - it’s becoming clear that relying on electricity for emergency exit functionality is a major issue.

The ruling has different implications for Tesla owners and car manufacturers overall. If NHTSA had opened an investigation into defects, Tesla might have faced recalls of specific cars within months. Now, though, new rules will be written to apply across all future vehicles - it’s going to take years, not weeks or months.

NHTSA recognized that people really need a safe way out in case their car gets into trouble. They acknowledged that building doors which rely on electricity for emergency exit functionality is flawed and makes it harder for panicked drivers or first responders to find the manual release when they’re in an emergency situation - that’s what NHTSA was reacting against with this decision.

While new rules are a step forward, it will take time before all cars comply. Millions of Teslas remain on roads today without these safety measures implemented yet - and until then, drivers can’t be certain they have the safest possible door egress system.

NHTSA opened an investigation into another Tesla issue last September after parents reported that their kids were getting trapped when trying to exit Model Ys with dead batteries. It shows how this problem of relying on electricity for emergency exits isn’t just isolated but a widespread concern across many car models.