In a sweeping safety action that marks the largest automotive recall of 2024, Tesla and four major Chinese electric vehicle manufacturers are pulling more than 4 million vehicles off Chinese markets to address hazards linked to popular hidden flush door handles, China’s top market regulator announced Friday.
The U.S.-based electric vehicle leader accounts for the vast majority of the recalled units, with 2.98 million affected vehicles including both China-produced and imported variants of its four core models: Model 3, Model Y, Model X, and Model S. Beijing-based technology conglomerate Xiaomi, which only recently launched its first line of consumer EVs, is recalling more than 390,000 units, while Hangzhou-headquartered EV startup Leapmotor is pulling over 370,000 vehicles. Established Chinese automaker Geely and leading EV brand XPENG are also conducting smaller recalls tied to the same safety issue, regulator data shows.
The recall action comes roughly eight months after Chinese regulators first announced that hidden door handles — a design widely adopted by EV makers to improve aerodynamic efficiency and extend driving range — will be banned for all new vehicles starting in 2027. Chinese officials have ramped up regulatory scrutiny of the flush handle design after a series of traffic accidents both in China and abroad documented cases where electronic hidden door handles failed to operate after severe collisions, trapping occupants inside and slowing emergency rescue efforts.
In the official notice posted to the State Administration for Market Regulation (SAMR) website, the regulator outlined the specific risk: in extreme crash scenarios that cause total vehicle electrical system failure, the non-mechanical hidden handles can block quick exit for trapped passengers and prevent first responders from gaining immediate access to the vehicle cabin. To resolve the hazard, Tesla will roll out free over-the-air software updates to all affected vehicles to adjust handle functionality, according to the regulator. Tesla has not yet issued an independent public comment or response to requests for clarification as of Friday.
People’s Daily, the official newspaper of the Communist Party of China, framed the industry-wide recall as a coordinated proactive safety upgrade for all existing vehicles ahead of the 2027 ban taking effect. The state publication noted that for China’s fast-growing new energy vehicle sector, industrial competitiveness depends not only on rapid technological innovation but also on meeting rigorous, consistent public safety standards.
The large-scale recall is one of the most high-profile regulatory actions taken by China in recent years to tighten oversight of the booming EV sector, which has grown exponentially to lead global electric vehicle production and sales. Industry analysts note the move signals Beijing’s growing priority on passenger safety as the segment matures, moving beyond a focus purely on market expansion and technological firsts.