2018 Chevrolet Volt

Issue Summary: The Chevy Volt has experienced recurring electrical problems, including the "Shift to Park" message, loss of power, and dead 12V battery. The vehicle had to be towed to the dealership three times due to these issues. One incident involved a power loss while driving at 65 mph, which caused a near-miss with a semi-truck, posing a significant safety risk. Warranty Status: The additional warranty was purchased, but only one of the three incidents occurred while the vehicle was under warranty. Safety Concerns: The repeated electrical failures, especially while driving at high speeds, raise serious safety concerns

EGR valve failure at highway speed of 70mpg on busy road with passenger and service dog in vehicle on a road trip (on ICE not electric). This produces a reduced propulsion in the vehicle and it becomes unsafe to drive. The EGR failure blew the 15A #3 fuse known as the "no walk home" fuse, so I needed to be towed to a parts store then unplug the EGR valve to make it somewhere safe. It was a Sunday, so every dealership (in the VA area at least) was closed. It is a well known/documented issue and the warranties have been extended, but only in a few states with the CARB protections. There are no warnings, if I was not an adept driver, we could all be dead. I also became stranded ~six hours from my home and only ~eight thousand miles outside of warranty. The replacement part costs ~$1800 without labor - the most expensive EGR valve the 60yr old parts employee at the dealership had ever seen, on a hybrid car which doesn't even truly require the part to operate or to pass emissions in some states. I think GM will help me with a goodwill repair in this case, as I have been a loyal Chevy customer my entire life and Volt owner since 2013 - but that is not the norm, so please take action and extend warranty protection to all Volt owners like the BECM issue.

Yesterday, my daughter was driving on [XXX] in Seattle traveling around 65mph when the vehicle lost power and reported the error of "shift to park", "Propulsion reduced" and "StabiliTrak failure". Luckily, she coasted to an off-ramp and safely put the vehicle in park. Thankfully she was not involved in an accident, but was very shaken by the experience. After doing some research it seems that the Chevy Volt has a known issue with the BECM and GM has failed to issue a recall, putting thousands of lives at risk. After turning the vehicle on and off several times, she was able to get it started and with minimal propulsion on residential streets was able to return to our house. this morning I dropped the vehicle at our local GM dealer for diagnosis and repair, but wanted to file a report, to hopefully prevent this from happening to another unsuspecting driver/child. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The BECM (Battery Electric Control Module) failed in November of 2023. Mountain Chevrolet has had my vehicle since then, claiming to be unable to find replacement battery module. The vehicle is available for inspection at Mountain Chevrolet (it has been left unlocked, unprotected, and exposed to the elements for almost 15 months now). When the BECM failed, the vehicle lost virtually all power and slowed dramatically from highway speeds to ~20 mph. There were no warnings prior to the failure.

Driving on gas on the highway, the adaptive cruise control suddenly disabled with a "Reduced Propulsion" message on the dash and a check engine light. The car started struggling in its propulsion. We found an AutoZone and scanned the codes, and multiple were returned. A Google search pointed us to the "walk home" fuse, which indeed had been blown. Replacing that fuse and disconnecting/reconnecting the battery eliminated the errors. Less than a week later during highway driving (the next time the battery charge was used up and it switched to the ICE) I got another check engine light, but this time without the "reduced propulsion" message. Scanning at AutoZone again revealed a P0404 message referencing the EGR valve. Due to the limited availability of the part I have called into Covert Bastrop (Bastrop, TX) and am waiting to hear back on their ability to fix the car.

The issue started with a forward push while lowering my speed while coming to a stop. It then progressed to a trembling engine. Then it progressed to the car struggling to effectively switch from electric to gas and back. It then would only be usable on electric range and the engine would not start and would be greyed out. Now, it only works on engine mode, it uses fuel like a pick up truck, it loses power while driving due to trying to switch to electric mode and back, and it struggles to accelerate. It will do it while idle as well as while driving 45mph and up. It barely has any propulsion power and I have to turn my hazards on any time I am going to accelerate. If I brake hard the engine will shake violently and then shut off. I then have to switch gears from drive to park or neutral to park to drive to reengage the engine. Recently it has turned on all the accessories but the ev and the gas is greyed out and there is zero propulsion power. I replaced the 12v battery thinking it might have been dying and it still has the same issue. I read about the class action lawsuit for the BCEM and have made an appointment the dealership but when I told them what was wrong with it the said we need to wait for the diagnostics.

On 9/18/24 I was driving my Chevrolet 2018 Volt on a freeway, traveling at approximately 55 mph while starting to exit the freeway. In the middle of fast-moving traffic, on the freeway offramp and starting to decelerate, the car suddenly displayed a message saying "Propulsion Power is Reduced." A micro-second later, the displayed message changed to read "Action Required: Shift to Park" and in that moment I lost control of the car's powertrain. I continued to break, coming to a slow stop in the middle lane of a multi-lane offramp, with other cars speeding past and around me. I attempted to power the car down and reboot it, moving the gear shift into "Park" position as instructed, but nothing changed. The car remained totally inoperable. I was on a slight decline and noticed the car moving forward pulled by gravity, so I steered the car to the farthest right of the offramp/parallel street, where I put my hazard signals on and requested the car be towed to a mechanic. I was endangered because the car lost entire propulsion while in the middle of fast-moving freeway traffic, and fellow motorists were endangered as well. I have learned that this same behavior occurs routinely with 2nd generation Volts; that there is a special bulletin related to the car's BCEM *and* a related class-action lawsuit posed against GM/Chevrolet. I requested Chevrolet take preemptive action to repair the BCEM, as I am fearful the issue will repeat and cause additional danger to myself and fellow motorists, but Chevrolet says they cannot repair the part until it is diagnosed as defective... which will occur when/if the part fails again, and I'm already in danger.

On 8/30/2024 I had driven my 2018 Volt (purchased new on 3/27/2019), with about 45,000 miles on it, on a normally 5 hour trip. About 3 hours into my trip on I-94 my car suddenly slowed down with a "Reduced Propulsion" message and a check engine light that came on. (The engine probably has run less than 25,000 miles of the total miles I have driven it, with the rest being purely on battery.) I was extremely fortunate to have been in the slow lane when the car suddenly stopped accelerating. This could have easily turned out very, very bad. The next day I had a dealer diagnose the car for a little over $400 - they told me there was a problem with my engines EGR valve and that the parts were back ordered so they couldn't give me an indication of when it could be repaired. I got the car back to my home dealer and they charged me another $200 to re-diagnose the problem and came the same conclusion of a bad EGR valve. They too have been unable to get a valve from GM. They have quoted me about $4,000 to have a new valve installed when they can get one. Heck, the car only has 45,000 miles on it!!