U.S. regulators are starting rulemaking on vehicle emergency exit access after Tesla door-handle cases.
Why it matters: A federal standard could force design changes beyond Tesla, affecting automakers, suppliers and compliance costs. The issue is now shifting from a company-specific probe to a broader safety rulemaking process.
- TechCrunch reported on July 23, 2026, that NHTSA will begin rulemaking over emergency exit access in vehicles.
- The agency chose rulemaking instead of a Tesla-specific defect investigation, according to the report.
- NHTSA’s DP25002 investigation focused on a 2022 Tesla Model 3 and whether emergency egress controls are readily accessible and clearly identifiable.
- TechCrunch said Tesla vehicles have manual inside door releases, but they are only located inside the car.
U.S. regulators are moving toward new requirements for how vehicle occupants can get out safely, after cases involving flush, electronically operated door handles, including Tesla's, raised concern about entrapment during electrical power loss or crashes.
In a July 23 report, TechCrunch said NHTSA will pursue rulemaking rather than a Tesla-specific defect action. The agency's public position, as quoted by TechCrunch, is that granting a petition for rulemaking does not mean a new standard is guaranteed - it starts a process of collecting input and public comments to decide whether a rule is appropriate under the Vehicle Safety Act.
NHTSA's ODI resume for DP25002 says the defect petition was prompted by a Tesla Model 3 emergency-egress issue. The investigation opened on Dec. 23, 2025, and centers on whether emergency egress controls are readily accessible and clearly identifiable. The vehicle population listed in the resume is 179,071.
The Transportation Department is already active on door-lock and door-retention standards. A Federal Register notice for FMVSS No. 206 shows NHTSA has a 2025 notice of proposed rulemaking tied to removing obsolete requirements.
TechCrunch also reported that NHTSA opened a door-handle investigation in September 2025 after nine owner complaints, including reports involving children, and found the handles may fail when the electronic lock system lacks sufficient battery voltage. Tesla design chief Franz von Holzhausen said in 2025 the company was working on a redesign, while Rivian said it is changing the interior door-handle layout on its R2 SUV to make the manual release more visible and closer to the powered handle.
By the numbers
- 9 - owner complaints cited by TechCrunch in NHTSA's September 2025 probe.
- 179,071 - estimated vehicles covered in the DP25002 investigation.
- 2025-12-23 - date NHTSA opened the DP25002 investigation.
Yes, but: NHTSA said granting the petition is not the same as issuing a new safety standard, so the process could still end without a rule.
What's next: NHTSA will gather information and public comments as it decides whether to propose a new standard.