On August 21, nine automakers simultaneously announced recalls for multiple vehicle models due to a door handle defect. The companies involved include FAW Group, BAIC BluePark, Dongfeng Motor, Chery, Geely, XPeng, Leapmotor, Tesla, and Xiaomi. Affected models span 20 vehicles, including the Tesla Model Y, Model 3, the 2024 Xiaomi SU7, Zeekr 007, Zeekr X, Leapmotor C01, Leapmotor C11, XPeng G6, XPeng P7+, and XPeng X9, among others.
According to the recall notices, the door handle issue is the primary cause, impacting over 4 million vehicles. The recalls cite that the interior emergency mechanical handles are similar in color to the interior trim, making them difficult to identify and operate. In extreme scenarios, such as a severe collision that disables the vehicle's low-voltage electrical system, this could impede occupants from quickly opening doors to escape and hinder external rescue efforts, posing a safety risk.
In recent years, vehicle safety has drawn increasing regulatory attention. A new mandatory national standard for automotive door handles will take effect on January 1, 2027. Although this new standard does not apply retroactively to existing vehicles, it does not mean the safety hazards of current door handles are being ignored. This large-scale recall represents a further regulatory step to address the safety of vehicles already on the road.
An automotive safety expert told reporters that the recalled models comply with current standards, but the safety risks of hidden door handles have become evident under the forthcoming new requirements. Using defect-based recalls to eliminate these risks is a reasonable approach.
Over 4 million vehicles recalled due to door handles
Among the more than 4 million vehicles recalled for door handle issues, Tesla accounts for nearly 70%. According to the announcement, Tesla will recall, starting September 25 this year, domestically produced Model 3 electric vehicles manufactured between March 4, 2019, and April 29, 2026, totaling 973,156 units. It will also recall domestically produced Model Y electric vehicles produced between November 16, 2020, and April 30, 2026, totaling 1,956,713 units.
Additionally, the recall includes 35,590 imported Model 3 electric vehicles, 8,328 imported Model X electric vehicles produced between October 27, 2022, and February 13, 2026, and 2,123 imported Model S electric vehicles produced between January 18, 2023, and February 10, 2026. Combined, Tesla's recall due to door handle safety hazards approaches nearly 3 million vehicles.
The other eight automakers have also scheduled recalls at different times. Xiaomi is recalling 339,069 units of its 2024 Xiaomi SU7 series pure electric vehicles produced between August 8, 2024, and March 4, 2026, plus an additional 51,366 units of the 2024 Xiaomi SU7 series produced between December 27, 2023, and August 16, 2024. Leapmotor is recalling 371,200 units of its C01 and C11 models. Geely is recalling 92,658 units of the Zeekr 007 and Zeekr X. Chery New Energy is recalling 68,500 units of the iCAR 03 and Fengyun X3. XPeng is recalling 264,800 units of the XPeng G6, XPeng P7+, and X9. Dongfeng Motor is recalling 53,452 units of the Nano 06, Fengshen L8, eπ007, and eπ008. BAIC BluePark Magna is recalling 46,850 units of the Arcfox Kaola pure electric vehicles. FAW Group is recalling 11,900 units of the EH7 and Tiangong 08.
Regarding the recall timeline, most automakers will begin recalls in August, while only Tesla and Chery New Energy will start in September. The remedial measures primarily fall into three categories: affixing warning labels at the interior emergency mechanical handle positions free of charge, upgrading window control software via over-the-air (OTA) technology to add a post-collision window lowering strategy, and replacing improved interior emergency mechanical handle covers.
A new mandatory standard era for automotive door handles
Vehicle safety has increasingly become a priority across the industry. Hidden door handles, in particular, pose potential safety risks that heighten the difficulty of escape and rescue in collisions or fire incidents. For example, electric exterior door handles and interior handles may fail during a power outage, and the absence of clear, standardized markings increases operational difficulty in emergencies.
Since last year, media outlets have continuously reported on the door handle safety issues of new energy vehicles and called for recalls of at-risk models. Following the release of the new mandatory standard, several automakers have already begun adjusting hidden door handle designs in their new vehicle plans.
Under the implementation timeline of the new mandatory standard, models applying for new door handle type approval must comply with all requirements except "hand operation space for opening doors" starting January 1, 2027, and must meet all regulations by January 1, 2028. Vehicles that have already received door handle type approval must comply starting January 1, 2029.
Although the new mandatory standard has not yet taken effect and does not apply retroactively to vehicles already sold, regulators can still invoke the defect recall system to address models with door handle safety hazards. The safety expert noted that the definition of a defect encompasses both property and personal safety. If a model is deemed defective by market regulatory authorities, a separate defect investigation and recall can be initiated.
This year, the Ministry of Industry and Information Technology organized the formulation of the mandatory national standard "Technical Requirements for Safety of Automobile Door Handles" (GB 48001-2026), which was approved and released by the State Administration for Market Regulation and the Standardization Administration of China. It is set to take effect on January 1, 2027.
This large-scale recall's key improvement directions align with the new mandatory standard's requirements. To prevent consumers from being "unable to find mechanical interior handles in emergencies," the new standard requires that door interior handles with mechanical release functions be easily identifiable by occupants. This includes ensuring handles are positioned without obstruction and are clearly visible from the occupant's seat, and when multiple mechanical interior handles are installed on a single door, operating any one of them should directly open the door.
Furthermore, the new standard stipulates that for door handles to open safely after a power failure, each door (excluding the tailgate) must be equipped with both mechanical exterior and interior door handles. In the event of an accident such as the deployment of irreversible restraint devices or a power battery thermal event while the locking mechanism is engaged, doors on the non-collision side should be openable without tools via the mechanical door handles. If a vehicle is equipped with electric interior door handles, it must also include mechanical interior door handles.
Addressing the risks of fully hidden door handles, the new mandatory standard explicitly requires sufficient hand operation space for the handles, with this space being no smaller than 60mm × 20mm × 25mm, meaning the operation space for opening the door by hand must not be less than 30 cubic centimeters.
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