Tesla and Major Automakers Launch Record-Breaking Vehicle Recall in China Over Safety Concerns Regarding Concealed Door Handles

Tesla and eight other automakers are initiating a massive recall affecting approximately 4.3 million vehicles in China. This unprecedented move comes amid growing safety concerns that emergency door releases may be difficult to locate or operate during critical situations, marking the nation's largest automotive recall to date.

Remedies for the affected vehicles range from remote software updates to the installation of warning labels and improved markings around door handles. Beijing has rolled out stricter safety regulations this year as intense competition fuels a fierce price war among manufacturers in the world's largest vehicle market. Furthermore, China announced plans to completely ban concealed door handles starting in 2027, making it the first country to phase out a design originally popularized by Tesla and widely adopted by domestic Chinese EV makers.

While Tesla did not immediately reply to a request for comment, Geely and Xpeng declined to comment on the matter. Xiaomi stated that it lacks additional information beyond the official regulatory notice. Meanwhile, Leapmotor reaffirmed its commitment to safety, explaining that its upgrade involves only a warning label and power-window control software, which is being handled in accordance with standard recall processes.

Most of the actions target emergency mechanical door-release handles that regulators argue can be hard to find or operate following a crash. This defect has drawn intense public scrutiny following several tragic incidents where passengers became trapped inside burning vehicles. Notably, Chinese state media reported in October that the driver of a Xiaomi SU7 sedan died after a crash and fire because bystanders were unable to open the doors to rescue him.

Tesla's recall is by far the largest, encompassing 2.98 million imported and China-made Model 3, Model Y, Model S, and Model X vehicles scheduled for recall beginning September 25, according to a statement from the State Administration for Market Regulation. The US automaker acknowledged that mechanical emergency door-release handles may prove difficult to identify following severe collisions and subsequent electrical system failures, potentially hindering occupant escape or rescuer access.

In addition to Tesla and Xiaomi, companies like Leapmotor, Xpeng, and Geely Holding announced their largest recalls on record based on filings submitted to SAMR. Xiaomi will recall roughly 390,000 vehicles, Leapmotor approximately 371,000, and Xpeng around 264,000, with other participating companies filing for much smaller recall volumes.

According to Sam Fiorani, vice president of research firm AutoForecast Solutions, the financial impact of these actions may remain limited. He noted that modern over-the-air updates significantly reduce both costs and vehicle downtime, while necessary physical modifications are far less expensive than major recalls of the past.

The flush-fitting door handles—which typically open via key fobs, smartphones, or touch-sensitive panels—have also caught the attention of US regulators. Last month, the US National Highway Traffic Safety Administration announced it would evaluate new safety standards to address the ongoing risk of occupant entrapment during electrical power failures, though NHTSA confirmed late Friday that automakers have not yet notified the agency of plans to file a similar recall in the US market.