Tesla Cybertruck Lawsuit Claims Defective Handle Design Caused Fatal Burn Injuries

Driver was unable to escape a fire so hot his bones may have broken from what is known as “thermal fracture.”

The family of a Texas man who burned to death inside a Tesla Cybertruck last year due to a battery fire has filed a wrongful death lawsuit, alleging that a series of critical design flaws prevented him from escaping the vehicle.

The complaint (PDF) was filed in Harris County District Court by Shannon Sheehan, the widow of 33-year-old Michael Sheehan, along with his parents, Richard Sheehan, Sr. and Sheila Butler. The lawsuit names Tesla, Inc. and a local bar, 3180 Bar, LLC, doing business as The Barn Whiskey Bar, as defendants.

The Tesla Cybertruck is a kind of electric vehicle powered by a lithium-ion battery, which have been under scrutiny for years due to their propensity for “thermal runaway.” Thermal runaway occurs when a battery’s increasing temperature leads to the generation of further heat in a chain reaction that often results in fires, explosions and the release of toxic gases.

Moreover, Tesla’s door locking and handle mechanisms have come under scrutiny in recent years, particularly for relying on electronic systems that may fail during power loss. In emergency situations, occupants have reported difficulty locating or using the manual release handles, which are not always intuitive or visible, raising concerns about entrapment during crashes or fires.

According to the lawsuit, Michael Sheehan purchased a 2024 Tesla Cybertruck from a Houston-area dealership on April 25, 2024. Just over three months later, on August 5, he was leaving The Barn Whiskey Bar in Cypress, Texas—where he had allegedly been over-served alcohol—when his Cybertruck veered off the road and struck a culvert, igniting a fire.

Although the crash was survivable, the complaint alleges the Cybertruck’s battery entered thermal runaway—a chain reaction in which damaged lithium-ion cells overheat and catch fire. Sheehan became trapped as the blaze intensified, reaching temperatures around 5,000 degrees Fahrenheit. The fire caused the vehicle to lose power, disabling its electronic doors. While Tesla includes manual release handles, the lawsuit claims they were difficult to locate in the emergency and not adequately explained during delivery.

“This was a single-vehicle crash. The structure of the BURNING CYBERTRUCK was compromised, but the crash forces themselves were survivable . . . except for the fire, ergonomic shortcomings, and deficient crashworthiness.”

–Shannon Sheehan et al. v. Tesla, Inc. and 3180 Bar

The family is pursuing strict liability claims, alleging that the Cybertruck’s design was dangerously flawed and that safer alternatives existed. The lawsuit points to volatile battery chemistry, lack of insulation, poor crash protection and emergency door handles that were hard to reach or use under duress. Tesla is also accused of failing to warn consumers about escape procedures during power loss or fire.

In addition to design issues, the complaint claims Tesla was negligent in its development, testing and customer training, and acted with gross negligence by ignoring known safety risks. The bar is also named as a defendant under Texas Dram Shop laws, with allegations that its staff continued serving Sheehan alcohol despite visible intoxication.

The complaint cites inadequate staff training, lack of intervention and failure to prevent Sheehan from driving as contributing factors. The family is seeking over $1 million in damages for wrongful death, including mental anguish, funeral costs, and pain and suffering endured in Sheehan’s final moments. A jury trial has been requested.

Electric Vehicle Door Concerns

In recent months, concerns around electric vehicle door safety extend beyond the Tesla Cybertruck.

Earlier this month, Ford issued a recall of its Mustang Mach-E electric vehicle, due to reports of passengers becoming trapped in the backseat when the lithium-ion battery is depleted.

The Mustang Mach-E recall follows a lawsuit filed in March, alleging that a design defect in the Ford vehicles leaves the electronically latching doors with no way of opening from the outside when the car battery dies, posing an increased risk of serious injuries or death to passengers.

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