Tesla Is Getting Sued Over Defective Model Y Door Handles
The Tesla Model Y's flush-mounted electronic door handles are under scrutiny after U.S. regulators started looking into more than 174,000 Model Y crossovers with door handles that could fail during emergencies—potentially trapping occupants inside.
Key Points
- NHTSA is investigating over 174,000 Tesla Model Y crossovers after reports that electronic flush-mounted door handles can fail in emergencies, trapping occupants.
- A Texas lawsuit claims the defect worsened crash injuries, after a passenger suffered severe burns when bystanders couldn’t open the doors of a burning Model Y.
- Tesla says a redesign is coming, but critics argue manual releases are inaccessible in many situations, raising the possibility of a recall.
The federal investigation coincides with Tesla defending a lawsuit stemming from a December 2023 crash in which a Tesla Model Y struck a utility pole and burst into flames after the driver suffered a medical emergency. According to court documents, bystanders were unable to open the passenger-side door because the electronic flush-mounted handles failed to deploy.
The passenger, Susmita Maddi, suffered severe burns and respiratory injuries before being pulled from the fire. Her legal team argue s that Tesla’s design was “defective and unreasonably dangerous,” claiming the vehicle was not reasonably crashworthy and that the locking system and door handles “were defectively designed.”
The Tesla Model Y received a five-star overall safety rating from the National Highway Traffic Safety Administration, alongside the Insurance Institute for Highway Safety naming the electric crossover a top safety pick.
The door handles have been in the news recently, with several other concerning incidents reported to NHTSA—including cases where parents had to smash windows to free children trapped in locked Model Ys due to a low-voltage battery. Federal regulators are now investigating whether the electronic locking system and battery issues could proliferate.
Tesla has recognized the concerns, with the automaker's head of design, Franz von Holzhausen, confirming it is reviewing the system and plans to redesign the mechanism to make it more intuitive. The company isn't interested in speaking publicly about the lawsuit, but has previously argued that manual releases inside the cabin remain available.
The lawsuit is now moving toward a jury trial in Texas. The plaintiff is seeking damages for medical expenses, lost income, disfigurement, and ongoing pain and suffering. Meanwhile, the NHTSA investigation could result in a recall affecting every 2021 Model Y sold in the U.S.
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An experienced automotive storyteller and accomplished photographer known for engaging and insightful content. Michael also brings a wealth of technical knowledge—he was part of the Ford GT program at Multimatic, oversaw a fleet of Audi TCR race cars, ziptied Lamborghini Super Trofeo cars back together, been over the wall during the Rolex 24, and worked in the intense world of IndyCar.
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