Tesla and Others Begin Record Vehicle Recall in China, 4.27 Million EVs Affected by Door Handle Safety Defect

Tesla and eight other automakers are recalling more than 4.27 million vehicles in China over a door handle defect that could trap occupants inside after a crash, marking the country's largest-ever automotive recall.

China's State Administration for Market Regulation has announced a sweeping recall affecting more than 4.27 million vehicles across nine automakers, including Tesla, Xiaomi, and Leapmotor. The recall, the largest in China's automotive history, addresses a safety defect in electronic door handles that could prevent occupants from escaping or rescuers from gaining access after a severe crash.

Tesla Accounts for Nearly 3 Million Vehicles

Tesla is the most affected manufacturer, recalling approximately 2.98 million vehicles across its Model 3, Model Y, Model S, and Model X lineups. The recall covers 973,156 China-made Model 3s, 1,956,713 China-made Model Ys, and a total of 46,041 imported vehicles. The issue stems from the interior emergency mechanical release, which is difficult to identify and operate because it closely matches the color of the surrounding trim.

The Safety Concern

In a severe crash that disables the vehicle's low-voltage electrical system, occupants may struggle to find and operate the emergency door release, potentially delaying escape and hindering rescue efforts. Bloomberg reported that at least 15 deaths have occurred in Tesla vehicles where occupants or rescuers were unable to open doors after crashes.

The Fix

Tesla will address the issue with a two-part solution: adding warning labels to identify the emergency mechanical release and deploying an over-the-air software update that automatically lowers the windows after a collision, providing an additional escape route . The recall takes effect on September 25, 2026.

A Coordinated Industry Action

Eight other manufacturers are participating in the recall, including Xiaomi (390,435 vehicles), Leapmotor (371,200 vehicles), Xpeng (264,840 vehicles), Geely, Chery, and others. The coordinated action comes as China prepares to ban hidden door handles entirely from 2027.

Separate Recall for Driver Monitoring

Tesla also announced a separate recall of 2.74 million China-made Model 3 and Model Y vehicles to upgrade its driver monitoring system, adding cabin camera monitoring alongside steering-wheel torque checks.

Here is the question this record recall raises. A 4.27 million-vehicle recall over door handles that can trap occupants after a crash highlights a fundamental design flaw in modern EVs. When regulators move to ban the technology entirely, and automakers are forced to retrofit millions of cars, what does it say about the industry's rush to prioritise aesthetics over safety?

As China tightens its safety standards and the US NHTSA begins its own rulemaking on door handles, the recall is likely to have global implications for how automakers design and test emergency egress systems.

FAQ:

Q: How many vehicles are being recalled in China over door handle safety issues?
A: A total of 4.27 million vehicles from nine automakers are being recalled, with Tesla accounting for nearly 2.98 million of them.

Q: Why are Tesla and other automakers recalling vehicles in China?
A: The recall addresses a defect in electronic door handles where the interior emergency mechanical release is difficult to locate and operate because it blends in with the interior trim, potentially trapping occupants after a crash.

Q: When does the Tesla recall in China take effect?
A: The recall takes effect on September 25, 2026.

Q: How will Tesla fix the door handle issue?
A: Tesla will add warning labels to identify the emergency mechanical release and deploy an OTA software update that automatically lowers the windows after a collision.

Q: What other manufacturers are involved in the recall?
A: Xiaomi, Leapmotor, Xpeng, Geely, Chery, BAIC BluePark, Dongfeng, and FAW are among the other automakers recalling vehicles.