China has launched the country’s largest recall of new energy vehicles, involving more than 4.2 million cars from nine automakers, including Tesla. The safety issue centers around concealed door handles that could pose risks in emergencies.
The recall was mandated by the State Administration for Market Regulation on August 21 and represents the biggest cross-brand recall linked to a single design flaw. Automakers have issued notices the same day, warning that emergency mechanical door releases are integrated into the interior trim and can be difficult to locate and operate. In severe crashes, where the vehicle’s 12-volt power supply fails, this problem could hinder occupants from quickly opening doors or escaping. It also complicates efforts for emergency responders to gain access from outside.
Tesla accounts for the majority of the recall, with nearly 2.98 million vehicles affected. These vehicles, produced from March 2019 to late April 2026, include both domestically manufactured and imported models, specifically the Model 3, Model Y, Model X, and Model S.
Other automakers with significant recalls include Xiaomi with 390,500 vehicles, Leapmotor with 371,200, Xpeng with 264,800, and Geely Holding with 92,658.
To resolve the issue, these companies are implementing various measures at no cost to owners. Solutions consist of adding warning labels near the emergency releases, using over-the-air software updates to enable windows to automatically lower after an accident for easier escape, and replacing handle covers to improve visibility.
Starting January 1 of next year, new national standards for automotive door handles will take effect. Experts have noted that the safety risks associated with hidden door handles are increasingly evident. Although these standards will not apply retroactively, it is considered reasonable for automakers to recall existing vehicles to mitigate hazards.
The concept of concealed pop-out door handles was first widely adopted in passenger cars by Tesla’s Model S, primarily for better aerodynamics, sleek design, and advanced appearance. This trend was subsequently adopted by numerous Chinese new energy vehicle manufacturers. However, as the design becomes more common, concerns about emergency situations have also grown.
In the event of a serious accident disabling electronic door release systems, exterior hidden handles could fail to deploy automatically, making rescue efforts more challenging. Although mechanical emergency releases are included inside the door, their low visibility and non-distinct covers can make quick access difficult, potentially limiting occupants’ chances of escape after an accident.