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2011 Chevrolet Volt

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2011 Chevrolet Volt do not stand out strongly from the model-year median of 169.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

38 reports with mileage · 11 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

2 crash reports0 fire reports1 injury reports

What owners actually said

49 reports
45,000 miles · Jan 27, 2015
Fuel/propulsion SystemStructure

MY FIRST PROBLEMS I EXPERIENCE WITH THE 2011 CHEVY VOLT WAS AROUND OCTOBER, 2014. WHEN DRIVING ON THE HIGHWAY AT HIGHWAY SPEED, I RECEIVED A "PROPULSION POWER REDUCED" INDICATION ON MY DASHBOARD AND I WAS NOT ABLE TO KEEP UP WITH HIGHWAY TRAFFIC WHICH RESULTED IN A HAZARD FOR MYSELF AND OTHER DRIVERS. I WAS AFRAID I WOULD BE REA…

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MY FIRST PROBLEMS I EXPERIENCE WITH THE 2011 CHEVY VOLT WAS AROUND OCTOBER, 2014. WHEN DRIVING ON THE HIGHWAY AT HIGHWAY SPEED, I RECEIVED A "PROPULSION POWER REDUCED" INDICATION ON MY DASHBOARD AND I WAS NOT ABLE TO KEEP UP WITH HIGHWAY TRAFFIC WHICH RESULTED IN A HAZARD FOR MYSELF AND OTHER DRIVERS. I WAS AFRAID I WOULD BE REAR ENDED OR CAUSE AN ACCIDENT DUE TO MY LOW RELATIVE SPEED. THIS HAS HAPPENED SEVERAL TIMES WHILE DRIVING MY VEHICLE, AT TIMES, NOT ABLE TO GO FASTER THAN 45-55 MPH ON HIGHWAYS WITH 65-75 MPH SPEED LIMIT. I LIVE IN SAN DIEGO CA WHERE THERE IS A LOT OF TRAFFIC ESPECIALLY ON THE HIGHWAY. I HAVE ALSO REVIEW THE LIFT GATE STRUCT "CUSTOMER SATISFACTION" DILEMMA. I HAVE HAD MY HATCH CLOSE ON MY HEAD BUT IT DID NOT CAUSE SERIOUS INJURY. IT WAS MORE OF AN ANNOYANCE THAN ANYTHING ELSE. IT CONTINUES TO BE WEAK, AND SOMETIMES NOT KEEP THE HATCHBACK UP AT ALL. I HAVE NOTICED IT IS WORSE AT LOWER TEMPERATURES (40-50 DEGREES F). LAST BUT NOT LEAST, I RECEIVED A NOTICE FROM GM STATING "THIS LETTER IS INTENDED TO MAKE YOU AWARE THAT SOME 2011 MODEL YEAR CHEVROLET VOLT VEHICLES MAY HAVE INCREASED FRICTION IN THE STEERING SYSTEM. THIS COULD CAUSE THE STEERING WHEEL TO STICK IN THE STRAIT-AHEAD POSITION AFTER DRIVING LONG DISTANCES ON A STRAIGHT HIGHWAY. THE STEERING WHEEL CAN BE TURNED BUT IT MAY REQUIRE INCREASED EFFORT." CONTACTED GM ABOUT THIS NOTICE I RECEIVED AND THE GM REPRESENTED ME SAID THERE WAS NO SAFETY ISSUE REGARDING THIS LETTER. I DISAGREED (HOW IS A STEERING WHEEL LOCK UP ON THE HIGHWAY NOT A SAFETY ISSUE?) AND REQUESTED TO GET OUT OF MY VEHICLE AND INTO A DIFFERENT ONE THAT DOES NOT HAVE THE POSSIBILITY OF MY AND MY FAMILY BEING KILLED BY A VEHICLE DEFECT. AFTER SEVERAL EMAILS BACK AND FOURTH AND GOING TO A CHEVY DEALERSHIP THEY TOLD ME TO GO TO, THE ISSUE HAS NOT BEEN RESOLVED. *TR

NHTSA ODI #10679070

31,000 miles · Apr 3, 2014
Steering

TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT. THE CONTACT STATED WHILE DRIVING 60 MPH AND ATTEMPTING TO MERGE ONTO THE SIDE OF THE ROAD, HE DROVE OVER THE RUMBLE STRIPS CAUSING THE VEHICLE TO VIBRATE AND THE POWER STEERING TO STOP WORKING. THE CONTACT MENTIONED THAT THE STEERING WHEEL BECAME VERY HARD TO MANEUVER AND THE CHECK POW…

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TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT. THE CONTACT STATED WHILE DRIVING 60 MPH AND ATTEMPTING TO MERGE ONTO THE SIDE OF THE ROAD, HE DROVE OVER THE RUMBLE STRIPS CAUSING THE VEHICLE TO VIBRATE AND THE POWER STEERING TO STOP WORKING. THE CONTACT MENTIONED THAT THE STEERING WHEEL BECAME VERY HARD TO MANEUVER AND THE CHECK POWER STEERING WARNING LAMP ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 31,000.

NHTSA ODI #10577125

28,606 miles · Mar 19, 2014
Air BagsElectrical SystemService BrakesCrashInjury

THE CAR HAS PROCEEDED TO HAVE MULTIPLE ISSUES, WITH THE MOST PREDOMINANT AND LIFE THREATENING ISSUE BEING AN AIRBAG FAILURE...TWICE. OTHER ISSUES: RADIO, DOOR LOCKS, AND PARK ASSIST ENGAGE/DISENGAGE ON THEIR OWN. BRAKES NOT CATCHING CAUSING CAR TO ROLL. POWER FAILURE AND WON'T START. APRIL 2013, THE VEHICLE WAS T-BONED AT A R…

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THE CAR HAS PROCEEDED TO HAVE MULTIPLE ISSUES, WITH THE MOST PREDOMINANT AND LIFE THREATENING ISSUE BEING AN AIRBAG FAILURE...TWICE. OTHER ISSUES: RADIO, DOOR LOCKS, AND PARK ASSIST ENGAGE/DISENGAGE ON THEIR OWN. BRAKES NOT CATCHING CAUSING CAR TO ROLL. POWER FAILURE AND WON'T START. APRIL 2013, THE VEHICLE WAS T-BONED AT A RATE OF SPEED OVER 45MPH. THE AIRBAGS FAILED TO DEPLOY; CAUSED PERSONAL INJURY. GM SENT OUT AN INSPECTOR, AND PULLED THE DATA. RESPONSE BACK WAS ?NO EVENT RECORDED? AND WAS DISMISSED. OBVIOUSLY SOMETHING HAPPENED, ESPECIALLY CONSIDERING THE CAR WAS IN THE BODY SHOP FOR 6 MONTHS BEING REPAIRED. JANUARY 2014 WHILE DRIVING DOWN THE HIGHWAY THE CAR LOSES POWER, AND WON'T ACCELERATE OVER 19MPH, THE CHECK ENGINE LIGHT ENGAGED AND ?REDUCED PROPULSION? MESSAGE FLASHING. ONSTAR DIAGNOSED THE VEHICLE INSTANTLY, AND SAID THE VEHICLE MAY BE UNSAFE TO DRIVE DUE TO THE TRANSMISSION AND ENGINE FAULT. WE REACHED OUT TO CLASSIC CHEVROLET GRAPEVINE, AND THEY WOULD NOT ASSIST US, EVEN THOUGH THE VEHICLE IS UNDER WARRANTY. JANUARY 2014, A SECOND COLLISION, A TRUCK CLIPPED THE FRONT OF THE CAR SPEED WAS OVER 35MPH, THE TIRE BLEW, AND SUDDEN DECELERATION, RESULTING IN $14,000+ IN DAMAGES AIRBAGS FAILED TO DEPLOY, AND CAUSING RE-INJURY. GM SENT OUT IT'S THIRD PARTY COMPANY TO INSPECT, AND AN EVENT WAS RECORDED THIS TIME, HOWEVER WAS A ?NON-EVENT? EVENT. GM STATES A EVENT WAS RECORDED, BUT COULD NOT EXPLAIN WHY THE AIR BAGS DID NOT DEPLOY. IN FEBRUARY 2014 WE REACHED OUT TO GM DIRECTLY, ASKING FOR CLARIFICATION, AND ASSISTANCE REGARDING OUR FLAWED 2011 CHEVROLET VOLT, AND WERE TOLD THEY ?RESEARCHED AND EVALUATED OUR CONCERN, AND FULFILLED ITS OBLIGATION? TO US. HOWEVER, THEY DID NOTHING. ANSWERED NO QUESTIONS, OFFERED NO RESOLUTION OR FIX. GM HAS A HISTORY OF NOT INVESTIGATING FATAL FLAWS, AND COVERING UP ITS NEGLIGENCE. *TR

NHTSA ODI #10573309

29,648 miles · Dec 21, 2013
Electrical System

AS AN ELECTRIC VEHICLE, WHEN RUNNING ON BATTERY, IT IS DIFFICULT TO KNOW WHEN THE VEHICLE IS LEFT RUNNING. UPON RETURNING HOME ONE DAY, I EXITED THE VEHICLE AND PLUGGED IT IN. I DIDN'T REALIZE AT THE TIME, THAT I HAD NOT TURNED OFF THE VOLT BY PRESSING THE BLUE POWER SWITCH ON THE DASHBOARD. THE NEXT MORNING, I CAME INTO MY E…

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AS AN ELECTRIC VEHICLE, WHEN RUNNING ON BATTERY, IT IS DIFFICULT TO KNOW WHEN THE VEHICLE IS LEFT RUNNING. UPON RETURNING HOME ONE DAY, I EXITED THE VEHICLE AND PLUGGED IT IN. I DIDN'T REALIZE AT THE TIME, THAT I HAD NOT TURNED OFF THE VOLT BY PRESSING THE BLUE POWER SWITCH ON THE DASHBOARD. THE NEXT MORNING, I CAME INTO MY ENCLOSED GARAGE AND COULD HEAR THE VOLT'S GAS POWERED GENERATOR RUNNING. I LOOKED AT THE DASH DISPLAY AND COULD SEE THE VOLT HAD NOT CHARGED, HAD USED UP ALL REMAINING BATTERY, AND HAD BEEN RUNNING ON GAS GENERATOR FOR SOME TIME. MY CONCERN IS REGARDING CARBON DIOXIDE POISONING RISKS. I HAVE TRIED OVER THE PAST 60 DAYS TO GET A RESPONSE OUT OF GM AS A VOLT OWNER AND I FEEL THEY ARE STONEWALLING ME AS THEY HAVE NOT RESPONDED TO ME ON THIS CONCERN DESPITE THREE DIFFERENT INQUIRIES ON MY BEHALF. THIS IS VERY UNUSUAL FOR GM WHO NORMALLY IS QUITE RESPONSIVE. I PROPOSE IF THE VEHICLE CAN SENSE IT IS PLUGGED IN THAT IT SHOULD SHUT DOWN SHOULD THE BATTERY BECOME DEPLETED RATHER THAN TURN ON THE GAS GENERATOR TO KEEP THE CAR RUNNING. I'M CONFIDENT GM CAN DETECT THE CAR IS PLUGGED IN SO PROGRAMMATICALLY I'M NOT UNDERSTANDING THE CHALLENGE TO SOLVE THIS SAFETY ISSUE. ELECTRIC CARS ARE NOT LIKE OTHER CARS IN THAT YOU CAN'T HEAR WHEN THEY ARE ON. CHANCES ARE, IF THE VEHICLE IS PLUGGED IN IT'S IN A GARAGE. NO GM EMPLOYEE WHO I HAVE SPOKEN WITH HAS EXPLAINED WHY IT'S REASONABLE TO RUN THE GENERATOR IN THE SCENARIO I HAVE DESCRIBED. I DO HOPE NO ONE DIES BEFORE THIS ISSUE IS RESOLVED. IT SHOULD BE A SIMPLE SOFTWARE UPDATE FOR THE VOLT TO RESOLVE THE ISSUE. *TR

NHTSA ODI #10556909

32,000 miles · Aug 5, 2013
Power Train

TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT. THE CONTACT STATED THAT WHILE DRIVING 10 MPH, THE VEHICLE DECELERATED WITHOUT ANY WARNINGS. THE CONTACT STATED THAT THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE…

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TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT. THE CONTACT STATED THAT WHILE DRIVING 10 MPH, THE VEHICLE DECELERATED WITHOUT ANY WARNINGS. THE CONTACT STATED THAT THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 32,000 AND THE CURRENT MILEAGE WAS 35,000.

NHTSA ODI #10533692

17,445 miles · Jul 18, 2013
Tires

TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT EQUIPPED WITH GOODYEAR ASSURANCE FUEL MAX TIRES, SIZE 215-55-17. THE CONTACT STATED THAT WHILE TRAVELING 70 MPH, THE FRONT PASSENGER'S SIDE TIRE BLEW. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS FOUND THAT THE FAILURE OCCURRED DUE TO LOW TIRE PRESSURE. THE TIRE WAS REPLACED…

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TL* THE CONTACT OWNS A 2011 CHEVROLET VOLT EQUIPPED WITH GOODYEAR ASSURANCE FUEL MAX TIRES, SIZE 215-55-17. THE CONTACT STATED THAT WHILE TRAVELING 70 MPH, THE FRONT PASSENGER'S SIDE TIRE BLEW. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS FOUND THAT THE FAILURE OCCURRED DUE TO LOW TIRE PRESSURE. THE TIRE WAS REPLACED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 17,445. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10525649

8,482 miles · Mar 26, 2012
Electrical System

OUR VOLT WAS LEFT OVERNIGHT TO CHARGE USING THE SUPPLIED 120V LEVEL ONE CHARGE CORD THAT COMES WITH THE VEHICLE (THEREFORE I CONSIDER IT PART OF THE VEHICLE.) IN THE MORNING THE VEHICLE WAS NOT CHARGED -- AT SOME POINT DURING THE NIGHT THE CHARGE FAILED AFTER THE BATTERY ACCUMULATED JUST 5 MILES OF ESTIMATED RANGE. THE SOCKET…

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OUR VOLT WAS LEFT OVERNIGHT TO CHARGE USING THE SUPPLIED 120V LEVEL ONE CHARGE CORD THAT COMES WITH THE VEHICLE (THEREFORE I CONSIDER IT PART OF THE VEHICLE.) IN THE MORNING THE VEHICLE WAS NOT CHARGED -- AT SOME POINT DURING THE NIGHT THE CHARGE FAILED AFTER THE BATTERY ACCUMULATED JUST 5 MILES OF ESTIMATED RANGE. THE SOCKET INTO WHICH THE CHARGE CORD HAD BEEN PLUGGED, THE RECEPTACLE OF A KILL-A-WATT CHARGE MEASURING DEVICE, WAS SCORCHED AND PARTIALLY MELTED. THERE MAY HAVE BEEN A SMALL ELECTRICAL FIRE AT THE POINT WHERE THE VOLT'S CORD PLUGGED INTO THE DEVICE, BUT IT IS IMPOSSIBLE TO SAY. THIS SEEMS TO HAVE HAPPENED BECAUSE THE STRAIN RELIEF ON THE CORD WAS TORN IN HALF AND THE WIRES IT WAS SUPPOSED TO PROTECT BECAME EXPOSED TO THE OUTSIDE AND PERHAPS TO EACH OTHER. IT IS QUITE LIKELY THAT THESE EXPOSED CHARGE CORD WIRES SHORTED AGAINST SOMETHING INSIDE THE CHARGE CORD ASSEMBLY, AND THAT SHORT CAUSED THE DAMAGE WHERE THE CORD WAS PLUGGED IN AT ITS WALL END. GUARANTY CHEVROLET TOOK POSSESSION OF THE CORD (AT GM'S REQUEST) AND ORDERED A NEW ONE UNDER WARRANTY, SO THE CORD ITSELF IS NO LONGER AVAILABLE FOR INSPECTION. I STILL HAVE THE KILL-A-WATT DEVICE, AND, DESPITE THE OBVIOUS VISIBLE DAMAGE, IT STILL WORKS. (I DON'T USE IT, THOUGH.) TO ME THE STRAIN RELIEF ON THIS CORD WAS VERY FLIMSY. THE MATERIAL SEEMED TOO SOFT AN PLIABLE TO DO VERY MUCH. THE REPLACEMENT SEEMED TO BE NO DIFFERENT APART FROM ONE ADDITIONAL FLEX SEGMENT. I WAS NOT IMPRESSED, BUT SO FAR THE FAILURE HAS NOT REPEATED. I HAVE PHOTOS IF YOU WOULD LIKE TO SEE THEM. PHOTOS OF THE OLD CORD, THE MELTED SOCKET AND THE NEW CORD. ALSO, I USED A NEW KILL-A-WATT ON THIS CAR AFTER THE INCIDENT AND ON OTHER ELECTRIC CARS WITH NO PROBLEMS. IT MAY BE TEMPTING TO BLAME THIS DEVICE, BUT IT HAS A SUFFICIENT AMP RATING AND THE PROBLEM HAPPENED ON A DAY THE STRAIN RELIEF FAILED. *TR

NHTSA ODI #10452948

12,000 miles · Oct 19, 2011
SuspensionWheels

THIS PROBLEM APPEARS TO BE A SAFETY ISSUE THAT I'M CONCERNED MAY IMPACT OTHER VOLTS. HERE'S THE BACKGROUND. ON SUNDAY AFTERNOON, I WAS PULLING INTO MY GARAGE AT A VERY SLOW RATE AND GOT HALFWAY THROUGH WHEN I HEARD A LOUD 'CRUNCHING' SOUND. I GOT OUT WONDERING WHAT THE THE NOISE WAS AND SAW THAT THE FRONT DRIVER'S SIDE OF THE C…

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THIS PROBLEM APPEARS TO BE A SAFETY ISSUE THAT I'M CONCERNED MAY IMPACT OTHER VOLTS. HERE'S THE BACKGROUND. ON SUNDAY AFTERNOON, I WAS PULLING INTO MY GARAGE AT A VERY SLOW RATE AND GOT HALFWAY THROUGH WHEN I HEARD A LOUD 'CRUNCHING' SOUND. I GOT OUT WONDERING WHAT THE THE NOISE WAS AND SAW THAT THE FRONT DRIVER'S SIDE OF THE CAR DOWN AND DIRECTLY SITTING ON THE TIRE. THE CONTROL ARM OR STRUT OR WHATEVER YOU CALL IT HAD SEEMINGLY COLLAPSED. LOOKING MORE CLOSELY, IT LOOKED LIKE THE WHEEL HAD PRACTICALLY COME OFF. GREASE WAS DRIPPING ONTO THE DRIVEWAY FROM UNDERNEATH. THE DEALER HAS NOW REPAIRED THE PROBLEM AND CLAIMS IT WAS A BAD BOLT, HOWEVER I AM NOT CONFIDENT THAT SUCH A MAJOR MANUFACTURING FLAW CAN BE SO EASILY DISMISSED. *TR

NHTSA ODI #10430808

55 miles · May 23, 2011
SteeringSuspension

THE REAR END OF THIS CAR FEELS AS IF IT IS SLIPPING OUT WHEN YOU ENTER A CURVE AT 60 TO 65 MPH. GM CALLS IT SENSITIVE STEERING BUT I CALL IT SCARY AND UNSAFE. *TR

NHTSA ODI #10402364

Official recalls

1

15V145000 · Electrical System:ignition; Engine And Engine Cooling:engine:gasoline

Mar 13, 2015

General Motors LLC (GM) is recalling certain model year 2011-2013 Volt vehicles manufactured August 25, 2010, to June 26, 2013. If the driver exits the vehicle without turning off the electrical system, the battery may drain low enough that the gasoline engine will automatically start itself to recharge the electric battery.

Consequence & remedy

Consequence: If the engine runs for an extended period of time in an enclosed space, there may be a build up of carbon monoxide, increasing the risk of personal injury.

Remedy: GM will notify owners, and dealers will update the engine management software to limit the time that the stationary vehicle can be left in the ON position, free of charge. The recall began April 15, 2015. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14617.

Additional source detail variants (2)

Electrical System:ignition

General Motors LLC (GM) is recalling certain model year 2011-2013 Volt vehicles manufactured August 25, 2010, to June 26, 2013. If the driver exits the vehicle without turning off the electrical system, the battery may drain low enough that the gasoline engine will automatically start itself to recharge the electric battery.

Consequence: If the engine runs for an extended period of time in an enclosed space, there may be a build up of carbon monoxide, increasing the risk of personal injury.

Remedy: GM will notify owners, and dealers will update the engine management software to limit the time that the stationary vehicle can be left in the ON position, free of charge. The recall began April 15, 2015. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14617.

Engine And Engine Cooling:engine:gasoline

General Motors LLC (GM) is recalling certain model year 2011-2013 Volt vehicles manufactured August 25, 2010, to June 26, 2013. If the driver exits the vehicle without turning off the electrical system, the battery may drain low enough that the gasoline engine will automatically start itself to recharge the electric battery.

Consequence: If the engine runs for an extended period of time in an enclosed space, there may be a build up of carbon monoxide, increasing the risk of personal injury.

Remedy: GM will notify owners, and dealers will update the engine management software to limit the time that the stationary vehicle can be left in the ON position, free of charge. The recall began April 15, 2015. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14617.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

DP22005 · Pedestrian Alert Sounds

Opened Jan 27, 2023 · Closed Aug 7, 2023

Status: closed (inferred from source dates) · Electrical System:propulsion System

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

PE11037 · Post-Crash Ev Fire Hazard

Opened Nov 25, 2011 · Closed Jan 20, 2012

Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery

The subject vehicles, which employ emerging technology, are range-extended electric vehicles that utilize a high voltage (HV) battery to provide energy for propulsion. The HV battery is lithium-ion based technology that has a nominal full charge of 390 VDC, a 16 kWh capacity, and a control system that incorporates liquid (antifreeze) cooling and various electronic devices (control modules, sensors, wiring, etc) to monitor and manage the HV battery. The HV battery, portions of the cooling system, and the control system are contained within a common enclosure.During an NCAP oblique side pole impact test conducted by NHTSA in May 2011, the pole struck and deformed the sill plate under the driver's door at a location where there is a structural member. The lateral member displaced inward, pierced the HV battery enclosure and battery, and caused a battery coolant leak. Thereafter, the Agency conducted a rollover test (the rollover test consists of four 90-degree rotate-and-hold movements about the vehicle's longitudinal axis). In that test, the HV battery and electronics were exposed to coolant that leaked as a result of the crash. The vehicle fire that occurred three weeks later and the additional testing NHTSA conducted are discussed in a report titled 2011 Chevrolet Volt Battery Fire Incident Report a copy of which is available in the public file. The report indicates that intrusion induced coolant leakage, and subsequent rollover that saturates electronic components, were the only test conditions which resulted in a subject vehicle HV battery fire.GM announced its intention to conduct a free-of-charge customer satisfaction campaign (CSP) on the subject vehicles on January 5, 2012. The action affects 14,735 vehicles produced prior to December 21, 2011. The CSP addresses three areas related to the issue under investigation. The first involves a modification/strengthening of the structure of the vehicle in the area where battery intrusion occurred in the May 2011 test. The second involves adding a sensor that detects excessive HV battery coolant loss, and control system software that then alerts the driver and prevents recharging of the HV battery. When the battery cannot be recharged, it will be depleted to a lower energy state as the vehicle continues to operate on the internal combustion engine. Lastly, a tamper-proofing device will be added to the system to prevent consumers from adding coolant. GM discusses these revisions in its response to an Information Request (IR) issued by NHTSA, noting that vehicles produced in calendar year 2012 and later will be manufactured to this condition.In December 2011, and at the same test facility, NHTSA repeated the May 2011 side impact test using a model year 2012 Volt modified to the structural condition described in the CSP. The test did not produce intrusion of the HV battery, a coolant leakage, or a fire (see test 7611, available at www.nhtsa.gov/Research/Databases+and+Software). In its IR response, GM describes four (4) additional side impact tests of modified subject vehicles it recently conducted using various build configurations and impact speeds (including higher speeds). GM reports that none produced HV battery intrusion, coolant leakage, or a fire.As noted in the complaint counts above, ODI has not identified a crash occurring in consumer's use of the vehicle that has resulted in a vehicle fire, or produced coolant leakage. ODI notes that side impact crashes with pole-like structures, such as would strike the sill plate, occur fairly infrequently, and such crashes with rollovers are even less frequent. A defect trend has not been identified at this time, and further investi