NHTSA Orders Tesla Records, Expands Door-Handle Probe

Federal safety regulators have expanded a defect investigation into Tesla’s flush‑mounted, retractable door handles after reports that low 12‑volt battery voltage or crash damage can render electronic handles inoperative and trap occupants. As of Oct. 27 the NHTSA said it had received 16 reports of exterior handles failing in certain 2021 Model Y vehicles and has broadened the probe to include peer vehicles — 2017–2022 Model 3s and 2020 and 2022 Model Ys. Complaints describe parents and children stranded, owners forced to break windows, first‑responder interventions, and at least one fatal 2024 Wisconsin crash now the subject of a wrongful‑death lawsuit alleging occupants were trapped. Regulators ordered Tesla to produce records by Dec. 10 and requested data on complaints, crashes, fires, injuries, warranties, software, latches and related lawsuits, warning of substantial fines for noncompliance. Tesla’s design chief said the company will alter future door‑handle designs as rivals and overseas regulators reconsider or move to mandate easier emergency interior releases, and multiple lawsuits across Tesla models have intensified scrutiny while NHTSA continues collecting evidence.