Tesla forced to recall 3M vehicles over 'hidden' car feature that poses 'safety hazard'

China has announced a recall of more than four million vehicles, including almost three million Tesla models, over a feature popularised by the Elon Musk-owned brand.

Cars from Tesla, Xpeng, Xiaomi and Geely are included in a massive recall of vehicles over flush door handles, which have become more common in recent years.

Concerns have risen in response to driver feedback, which found that hidden door handles are difficult to locate and can pose issues in the event of an emergency.

Any recalled vehicles, including 2.98 million Tesla models, will have a warning label stuck on the interior of the door.

All of these vehicles will also receive a software update that will automatically lower the windows in the event of an accident.

Scrutiny was raised earlier this year following two fatal crashes involving Xiaomi's electric vehicles, amid fears that a power failure prevented doors from opening.

China's Ministry of Industry and Information Technology confirmed in February that it would be banning certain vehicle designs, including flush door handles.

The new ban will require a mechanical release on the inside and outside of the doors, with these rules set to be enforced from January 1, 2027.

Chinese state media outlined that passenger door handles must have a recessed space of more than 6cm by 2cm by 2.6cm to allow access.

Reports at the time stated that vehicles already approved for sale and in the final stages of entering the market will have a two-year grace period.

In a filing with the State Administration for Market Regulation, Tesla said 2.98 million imported and Chinese-made Model 3, Model Y, Model S and Model X vehicles would be recalled.

A statement from Tesla said that a severe collision could cause the vehicle's low-voltage system to fail, although this was only in "extreme situations".

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It warned that this could "hinder occupants from quickly opening the doors to escape and impede rescue efforts by those outside the vehicle, posing a safety hazard".

Separate filings show that 390,000 Xiaomi vehicles will be recalled, in addition to 371,000 Leapmotor models and 264,000 Xpeng cars.

Speaking to the BBC, Tu Le, founder of Sino Auto Insights, warned that warning labels and software updates would not be a lasting solution to the issue.

Car brands adapted to the flush door handles last decade following the success of the Tesla Model S sedan, which Mr Le described as "sleek".

China Daily reported that around three in five of the 100 best-selling "new energy vehicles" in China have hidden or flush door handles.

The ban only impacts vehicles sold in China, although this decision could pressure car brands into moving away from the design feature for all of their vehicles.