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China Orders Mass Recall of 1.7 Million Electric Vehicles Over Door Lock Failures

Tesla and eight other automakers must fix emergency exit systems after reports of occupants trapped inside vehicles during crashes.

By Sarah Kim··3 min read

China's State Administration for Market Regulation has ordered nine automakers to recall approximately 1.7 million electric vehicles to address critical safety defects in their door locking mechanisms, marking the largest automotive recall in the country's history.

The regulatory action, announced Friday, targets emergency exit systems that can malfunction during crashes or electrical failures, potentially trapping occupants inside vehicles. Tesla accounts for a significant portion of the affected vehicles, though the recall also encompasses major Chinese manufacturers including BYD, NIO, and Li Auto, according to the regulator's statement.

The defect centers on electronic door locks that require electrical power to operate. When a vehicle's battery system is compromised in a collision or fire, these locks can fail to release, leaving passengers unable to open doors from the inside. Several incidents in China reportedly involved occupants struggling to exit vehicles after accidents, though the regulator did not disclose specific casualty figures.

Parallel Concerns in the U.S.

The safety issue mirrors ongoing litigation against Tesla in the United States, where multiple lawsuits allege that the company's electronic door release systems have contributed to injuries and deaths. In several cases, plaintiffs claim that occupants became trapped in burning Teslas after crashes disabled the primary electronic door releases.

Tesla vehicles typically feature electronic buttons or switches for door operation rather than traditional mechanical handles. While the cars include manual emergency releases, these backup mechanisms are often unfamiliar to passengers and can be difficult to locate during high-stress situations. Critics argue this design prioritizes aesthetics over safety, particularly when many users are unaware the manual releases exist.

The Chinese regulator's action suggests authorities view the risk as sufficiently serious to mandate hardware or software modifications across multiple manufacturers, rather than relying on consumer education alone.

Technical Remediation Required

Affected automakers must submit detailed remediation plans to Chinese regulators within 30 days. The fixes will likely involve a combination of software updates and hardware modifications, according to automotive safety experts.

Potential solutions include: implementing automatic door unlocking when airbags deploy, adding battery backup systems for door locks, making manual release mechanisms more prominent and intuitive, or redesigning door systems to default to unlocked positions when power is lost.

The recall affects vehicles manufactured between 2019 and 2026, spanning multiple model years and representing a substantial cross-section of China's rapidly growing electric vehicle fleet. China is the world's largest EV market, with electric vehicles accounting for more than 35% of new car sales in 2025.

Regulatory Implications

The coordinated recall across multiple manufacturers suggests Chinese regulators identified a systemic design flaw rather than isolated manufacturing defects. This approach differs from typical recalls that target specific production batches or model years from individual companies.

Industry analysts note that China's willingness to impose such a sweeping recall on both foreign and domestic automakers demonstrates the government's increasing focus on EV safety as adoption accelerates. The action comes as Chinese authorities face pressure to address public safety concerns that could undermine confidence in electric vehicle technology.

For Tesla, the recall adds to mounting scrutiny of its safety practices in China, its second-largest market. The company has previously faced regulatory pressure in the country over data security, customer service practices, and quality control issues.

The remediation costs will vary by manufacturer depending on the technical solutions required. Software-based fixes would be less expensive than hardware replacements, though some vehicles may require physical modifications to door mechanisms or the addition of backup power systems.

Automakers have not yet announced specific timelines for implementing the fixes, though Chinese regulations typically require recalls to begin within 60 days of regulatory approval of remediation plans. Vehicle owners will likely receive notifications directing them to schedule service appointments at authorized dealers.

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