Tragedies of Trapped Victims Mount! China Bans 'Hidden Door Handles' Nationwide: 9 Automakers Recall 4.3 Million Vehicles, Ban Effective from 2027

Tesla and eight other automakers have announced the recall of approximately 4.3 million vehicles in China, setting a record for the largest automotive recall in the country's history. Corrective measures include software updates, the addition of warning labels, and improved signage around door handles. Most automakers will also perform over-the-air (OTA) remote software upgrades.

According to an announcement by China’s State Administration for Market Regulation, Tesla will begin recalling 2.98 million imported and domestically manufactured Model 3, Model Y, Model S, and Model X vehicles starting September 25. Tesla’s recall is the largest, reflecting the high sales volume of its vehicles featuring this door handle design.

As reported by China Business News, in addition to Tesla, the recall involves automakers including FAW Group, BAIC Blue Valley, Dongfeng Motor, Chery, Geely, XPeng, Leapmotor, and Xiaomi. Xiaomi will recall approximately 390,000 vehicles, Leapmotor about 371,000, and XPeng about 264,000. The recall sizes for Leapmotor, XPeng, and Geely also mark historical records for their respective companies. Reuters noted that the scale of this recall reflects both China’s massive vehicle ownership and regulators’ increasing scrutiny of safety defects as vehicles become more reliant on software.

Difficulty Opening Doors in Emergencies

The recall primarily targets mechanical door unlock devices used in emergencies. Chinese regulators stated that after a severe collision disables the vehicle’s electrical system, the mechanical emergency door unlock mechanism may be difficult to identify. This could prevent occupants from escaping and hinder rescuers from entering the vehicle.

Tesla’s corrective measures include adding warning labels and implementing a remote software update that automatically lowers windows after a collision. This issue has drawn growing attention in recent years, following several incidents where passengers were trapped inside burning vehicles.

In October last year, Chinese state media reported that after a Xiaomi SU7 collided and caught fire, bystanders were unable to open the doors to rescue the driver, who ultimately died.

Why Electronic Door Handles Spark Safety Controversy

In recent years, electronic door handles have rapidly gained popularity in the global automotive market, especially in the electric vehicle sector. This design was widely popularized by Tesla. The handles are typically flush with the vehicle’s surface, aiming for a minimalist appearance while reducing aerodynamic drag. When the owner approaches the vehicle, the handles usually pop out automatically via an electronic system.

However, unlike traditional mechanical door handles, these doors typically rely on buttons, touch panels, or electronic systems to open. Michael Brooks, Executive Director of the Center for Auto Safety in the United States, said that if there is no clear and reliable manual unlocking method after a vehicle loses power, drivers and passengers may struggle to escape in life-threatening situations.

He noted that some automakers’ designs are relatively intuitive—for example, pulling the interior door handle twice in succession triggers manual unlocking. However, Tesla’s manual emergency release is often located inside the door storage compartment or beneath a panel and lacks clear labeling.

Automotive consulting firm J.D. Power previously pointed out that as manufacturers continue redesigning door handles, the basic functionality of door operation has become an increasingly problematic area. At the time, J.D. Power stated that seven out of the top ten models with the most prominent door handle issues were electric vehicles.

Multiple lawsuits have alleged that Tesla’s door handle design prevented drivers or passengers from escaping burning vehicles, resulting in injuries or fatalities. Some drivers have also filed complaints with the U.S. National Highway Traffic Safety Administration (NHTSA), stating they were unable to open doors after exiting the vehicle to rescue children from inside.

China to Ban Hidden Door Handles from 2027

This year, China has strengthened oversight of the electric vehicle industry and announced in February that it will ban “hidden” door handles starting in 2027—becoming the first country globally to implement such a measure.

Under the new safety requirements, all doors must be equipped with interior and exterior handles. Mechanical opening mechanisms will become mandatory, while electric handles and other innovative designs will remain optional. The new policy also specifies the installation position and function of external door handles to ensure doors can be opened during accidents.

Chinese authorities stated that starting January 1, 2027, newly approved vehicle models must comply with the new handle design rules. Existing approved models must meet the standards by January 1, 2029.

In the United States, proposed legislation would require vehicles with such door handles to include reliable manual opening mechanisms. In Europe, regulators identified risks associated with electronic door handles as a priority concern last year. The United Nations Economic Commission for Europe (UNECE) is currently developing new standards to ensure electronic door handles can be opened from both inside and outside even after a power failure.

Recall Costs May Be Relatively Limited

Although the recall affects approximately 4.3 million vehicles, industry insiders believe the associated costs may not be particularly high. Sam Fiorani, Vice President at automotive research firm AutoForecast Solutions, said the recall cost is likely to be relatively limited. He explained that modern vehicles’ OTA remote upgrade capabilities reduce the cost and downtime associated with large-scale recalls, and even physical repairs would not incur the high expenses seen in past major recalls.

It remains unclear whether Tesla will conduct similar recalls in the U.S. or Europe. Automotive safety regulators in the U.S. and Europe, as well as Tesla, did not immediately respond to requests for comment. Michael Brooks of the U.S. Center for Auto Safety noted that a recall in one country does not necessarily mean automakers will take the same action in other markets. He added that Tesla might still challenge a recall request in the U.S.

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