This informational bulletin instructs the tech when fuel/fluid is needed to be tested and where it can be sent for analysis.
full bulletin at NHTSA ↗2016 Chevrolet Spark brakes problems
severe 19 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
19
Recalls
0
Avg fix
$450
1crash
1injury
When does it fail?
Of the 19 brakes complaints filed for the 2016 Chevrolet Spark, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 6 model years of Chevrolet Spark we track for brakes problems, this one carries the most owner complaints on file — 19.
Brakes accounts for 45% of every owner complaint on file for this vehicle — the dominant problem area across 4 categories tracked.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This service bulletin provides diagnostic/repair information to correct customer concerns of a Crank No Start or Extended Crank, Malfunction Indicator Lamp (MIL) Illuminated or Possible Increased Brake Pedal Effort.
full bulletin at NHTSA ↗This Preliminary information communicates that when removing the fuel line jumper hose care should be taken to be sure the line is reinstalled correctly to avoid a no/low fuel pressure situation.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report multiple distinct brake failures in the 2016 Spark: sudden total loss of brake assist forcing them to push the pedal to the floor with minimal stopping power, complete brake failure while driving (some occurring within 37 miles of purchase), and hard or unresponsive brakes requiring extreme pedal pressure. Warning lights—Service Brake Assist and Service StabiliTrak—typically flash together just before loss of function. Some owners describe it as losing power brakes entirely, pushing back on the pedal like manual brakes. Extended stopping distances are common; one owner coasted nearly 2 miles downhill unable to stop. Symptoms often resolve temporarily after shutdown and restart. EV-specific complaints involve rough transitions between regenerative and mechanical braking, sudden lock-up, and suspected deactivation of regenerative braking. Brake booster failure, vacuum pump fracture, and wheel cylinder defects are also cited. Dealership repairs—pedal assembly replacement, brake module swaps, system overhauls costing $1,583—have not consistently resolved the problem. Some owners report being stuck at dealerships for 10+ days without a fix, while others note parts are out of stock. One owner reported rear wheel sensor suspected as faulty but unavailable. The intermittent nature makes diagnosis difficult; some independent shops cannot replicate issues.
Failure modes owners describe
Brake Assist Failure (Power Braking Loss)
The power brake assist system suddenly fails, causing the brake pedal to sink toward the floor with minimal stopping force. The vehicle must be stopped by applying extreme pedal pressure or using the transmission to slow down. Service Brake Assist and Service StabiliTrak warning lights appear together.
When: Onset from ~37 miles (brand new vehicle) to 36,569 miles. Multiple occurrences reported within single ownership periods. Events often follow light rain or damp conditions, but also occur in dry conditions.
Symptoms owners cite: Brake pedal sinks most of the way to the floor with minimal braking capacity; Extreme effort required to decelerate; feels like loss of power braking entirely; Service Brake Assist warning light; Service StabiliTrak warning light; Warning lights often appear together immediately before loss of braking; Symptoms may resolve temporarily after vehicle shutdown and restart
Codes mentioned: Service Brake Assist warning, Service StabiliTrak warning, ABS warning (reported in some cases)
Repairs/costs cited: Dealerships have replaced pedal assembly multiple times without resolving issue in some cases. Brake modules replaced. Body Control Module replaced in one case. Some vehicles still unresolved after fourth dealership visit. Repair costs cited: $1,583.97 for complete brake system replacement in one case.
Recalls/TSBs owners mention: Multiple dealership visits without consistent resolution in some cases. One owner reported dealership was unsure how to fix the problem as of 10 days into the fourth service attempt. One owner reported parts out of stock in the U.S.
Complete Brake Failure
Total loss of braking function while vehicle is in motion. Pedal goes to floor with virtually no stopping force. Vehicle continues at speed or slows dangerously over extended distance. Service Brake Assist, StabiliTrak, ABS, and other warning lights illuminate.
When: Multiple occurrences reported from brand new (37 miles) to used purchase. Events occur on city streets, highways, during stop-and-go traffic, and on downhill grades.
Symptoms owners cite: Brake pedal goes completely to floor with no effect; Vehicle fails to stop or barely slows when brakes are applied with maximum force; Extended stopping distance (one owner reported ~2 miles on downhill grade before able to stop); Service Brake Assist light; Service StabiliTrak light; ABS warning light; Emergency brake light (in some cases); Brake system appears normal after vehicle shutdown and restart
Codes mentioned: Service Brake Assist warning, Service StabiliTrak warning, ABS warning, Emergency brake light
Repairs/costs cited: One owner reported dealership technician found zero brake pressure and stated brake pressure modulator needed replacement. One independent shop could not replicate issue and reported vehicle working as intended.
Recalls/TSBs owners mention: Brake modules replaced in some cases. One vehicle towed to dealership after failure on day of purchase. One owner reported dealership unsure of resolution.
Brake Booster / Vacuum Pump Failure
The brake booster fails or the vacuum pump that supplies it becomes inoperative, causing the brakes to feel extremely hard and requiring excessive pedal force to stop the vehicle. Owner reported this was described as a rare occurrence but said multiple complaints exist.
When: One case reported; timing not specified beyond general operation.
Symptoms owners cite: Brake pedal becomes very hard to press; Inability to stop vehicle quickly despite full pedal application; Extended stopping distance (one owner reported quarter-mile of travel before complete stop); No warning signs reported by owner
Repairs/costs cited: Brake booster replaced. Brake booster vacuum also needed replacement. Owner noted technician stated this rarely happens but there are multiple complaints.
Brake Wheel Cylinder Defect
The brake wheel cylinder is defective, causing abnormal braking noise without warning. After dealership repair and replacement, the same failure recurs.
When: Reported at approximately 9,659 miles.
Symptoms owners cite: Abnormal noise from brakes during low-speed operation; No warning before occurrence
Repairs/costs cited: Wheel cylinder replaced. Brakes adjusted. Failure recurred after repair.
Recalls/TSBs owners mention: Manufacturer was notified.
Brake Vacuum Pump Failure (Engine Brake)
The engine brake vacuum pump fractures or breaks into pieces, losing vacuum seal and preventing brake assist. Debris from broken pump has fallen into engine during repair.
When: Two incidents reported by same owner during highway and main road driving.
Symptoms owners cite: Brakes lock completely; Loss of brake assist function; Pump found broken in pieces
Repairs/costs cited: Engine brake vacuum pump replaced on two separate occasions. Metal debris from broken pump fell into engine, requiring retrieval to prevent engine damage.
Regenerative Braking System Malfunction (EV-Specific)
Regenerative braking system unexpectedly deactivates or transitions abruptly to mechanical-only braking, causing sudden changes in pedal feel and reduced braking force. When regenerative braking is not available, mechanical brakes feel softer with longer stopping distances.
When: Multiple occasions reported as of September 2017; occurs during warm, dry daylight driving between 30–40 mph.
Symptoms owners cite: Sudden decrease in braking force despite firm pedal application; Significantly increased pedal travel; Significantly longer stopping distances; Pedal feel similar to post-100%-charge condition (before regenerative braking available); Brakes function normally before and after incident; Occurs when battery in state of partial discharge
Repairs/costs cited: Owner suspects unexpected deactivation of regenerative braking system. Owner noted similar conditions never occurred in two years with Fiat 500e on same route.
ABS / Regenerative Braking Lock-Up
The ABS or regenerative braking system over-reacts during braking application, locking wheels and rendering the brake pedal ineffective for brief periods. Clicking or grinding noise may accompany the event.
When: Intermittent events; owner reports running stop lights and stop signs while approaching at safe speeds.
Symptoms owners cite: Brake stuttering or pulsating; Complete brake failure for brief periods during application; Rear right wheel may make clicking or grinding noise during event; Brake pedal becomes ineffective at stopping vehicle; Vehicle runs red lights and stop signs despite safe approach speeds
Repairs/costs cited: One owner noted all dealerships were at a loss for resolution and parts are out of stock in the U.S. Rear wheel sensor suspected as faulty.
Transition Between Regenerative and Mechanical Braking (Sloppy / Abrupt)
The switch from regenerative to mechanical braking is abrupt and poorly tuned. When mechanical brakes engage, they do so with excessive force, causing wheels to lock and ABS to activate.
When: Reported as ongoing issue affecting normal braking transitions.
Symptoms owners cite: Sloppy, abrupt transition between regenerative and mechanical braking; Mechanical braking engages too strongly when regenerative is unavailable; Wheels lock suddenly; ABS activates due to sudden lock-up
Brake Pulsation and Pulsating Pedal on Startup
Brake pedal pulsates abnormally when vehicle is first started. A loud sound accompanies the pulsating from the front left of the vehicle. Warning lights (ABS, StabiliTrak, Service Brakes) activate.
When: Observed at start of commute after vehicle has been parked.
Symptoms owners cite: Brake pedal pulsates; Loud sound from front left portion of vehicle; ABS warning light; StabiliTrak warning light; Service Brakes warning light; Continued pulsating and sound as vehicle is driven
Codes mentioned: ABS warning, StabiliTrak warning, Service Brakes warning
Repairs/costs cited: Brake modules replaced (owner reported on 10/3/2016); pulsation did not recur on first occurrence but complete brake failure did on subsequent event.
Synthesized from 19 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 8 most recent
I was driving a 2016 Chevrolet spark EV on a city roadway when I had a complete brake failure and almost was involved in a collision. At the start of my commute, I turned the vehicle on which was parked on the outside of the garage. I noticed that there was a loud sound coming from the front left portion of the vehicle as the brake pedal was pulsating. As I pulled out onto the roadway the…
I was driving downhill with the car in L on a highway and brakes failed. I could not engage the brakes at all but somehow the car slowed to a stop and I managed to pull into a parking spot and park. Two lights came on: Service Intellitrak and Service Brake Assist. The car has been inspected by the Chevrolet dealership that sold the car to me as well as an independant shop. One technician at the…
Braking system inconsistent performance. Transition from regenerative braking to mechanical braking is sloppy and abrupt. When the mechanical braking system kicks in, it kicks in too strong causing the ABS system to activate as the wheels suddenly lock up.
Sudden and strong brake pedal applications occasionally resulted in significantly more pedal travel, significantly less braking force, and significantly longer stopping distances than typically experienced during similar brake pedal applications. Each event occurred on warm, dry southern california streets during daylight hours, traveling between 30-40 MPH. On each occasion, the brakes --…
Tl* the contact owns a 2016 Chevrolet spark. While being operated at a low speed, the brakes made an abnormal noise without warning. The vehicle was taken to classic Chevrolet (located at 1101 w state highway 114, grapevine, tx) where it was diagnosed that the brakes needed to be adjusted and the brake wheel cylinder was defective and needed to be replaced. The vehicle was repaired; however, the…
On the way back to my san francisco home from the novato Chevrolet dealer where I had just purchased a new black 2016 Chevrolet spark EV my brakes stopped functioning. Just coming off the golden gate bridge, on a significant downhill grade, my brakes stopped functioning properly. At first the brakes started to be harder to push and then with my foot to the floor, provided almost no stopping…
I own a 2016 Chevy spark bought on january 2020. Over the last week (july 15) at 36,569 miles my brakes have become significantly weaker where I'm pushing my foot all the way to the floor to stop the vehicle. Backing out of my driveway which is fairly steep, my brakes won't stop my car unless pressed as far possible to the floor. I thought my pads needed changing but upon inspection they still…
Both Brake Assist and stabilitrack go out in conjunction with failure lights (no fore-warning). The vehicle was repaired by a Chevrolet dealership with qualified EV tech. Within two weeks that same brake system failures occurred. The issue greatly increases the force needed to press the brake pedal and lengthens braking distance significantly. it also causes a failure in the braking system while…
Had brakes trouble with your 2016 Chevrolet Spark?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2016 Chevrolet Spark?
It's a meaningful issue. 19 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 14 complaints that reported odometer mileage, most brakes failures cluster between 2,741 and 31,000 miles, with the median around 4,600. A quarter of owners report trouble before 2,741; a quarter make it past 31,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2016/Chevrolet/Spark.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.