This Warranty Administration service bulletin provides Lithium-Ion battery Exchange Process and Transaction Submission information.
full bulletin at NHTSA ↗2016 Chevrolet Volt electrical problems
moderate 52 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
52
Recalls
0
Avg fix
$850
When does it fail?
Of the 52 electrical complaints filed for the 2016 Chevrolet Volt, 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
Electrical accounts for 31% of every owner complaint on file for this vehicle — the dominant problem area across 4 categories tracked.
Owners have filed 52 electrical complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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 Warranty Administration service bulletin provides Lithium-Ion battery Exchange Process and Transaction Submission information.
full bulletin at NHTSA ↗This service bulletin provides information on the proper Reflective High Temperature Heat and/or Insulating Tape to use for certain repairs, such as Wiring Harness Repairs.
full bulletin at NHTSA ↗The intent of this service bulletin is to identify aftermarket ALDL or DLC interface devices as potential sources for causing multiple customer concerns that do not have other diagnostic methods to identify them.
full bulletin at NHTSA ↗This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2016 Chevy Volt has widespread electrical and propulsion control failures. The Battery Energy Control Module (BECM) is the most serious: it fails intermittently or completely, causing loss of all motive power while driving, inability to start, or stalling. Owners report 'Propulsion Power Reduced,' 'Engine Unavailable,' or 'Shift to Park' messages appearing even when the vehicle is already in park, sometimes trapping them unable to shut off the car. Replacement costs $2,000–$5,000, and while GM issued Special Coverage Bulletin N232432680 in March 2024 covering 2016–2018 models, many CARB-compliant vehicles are excluded—roughly 67% of 2016 production—despite exhibiting identical symptoms.
EGR valve failures are equally common, occurring around 47,000–83,500 miles. The valve shorts electrically, blowing Fuse 3, which also controls the engine oil pressure solenoid, coolant thermostat, and oxygen sensor. This leaves the vehicle in limp-mode or unable to move, with engine overheating risk. Owners report extreme difficulty obtaining replacement parts—some face 12+ month backorders—and costs around $1,140–$1,927 for the valve alone.
Owners also report intermittent center display blackouts at startup and water intrusion into connectors causing false sensor activations. One owner was denied BECM coverage because their vehicle carried a salvage title. Across narratives, owners describe these failures as safety hazards capable of leaving them stranded on highways.
Same Chevrolet Volt electrical reports on nearby years: 2013 · 2014 · 2015 · 2017 · 2018
Failure modes owners describe
Battery Energy Control Module (BECM) Malfunction
The BECM fails intermittently or completely, causing loss of propulsion, inability to start, inability to charge, or stalling while driving. Owners report the vehicle becomes undrivable, displaying 'Propulsion Power Reduced' or 'Engine Unavailable' messages, and may not shift out of park or respond to acceleration inputs.
When: Between 13,000 and 160,800 miles; typically 40,000–150,000 miles
Symptoms owners cite: Loss of all motive power while driving; Stalling or inability to restart; Check engine light (CEL) on; Message 'Propulsion Power Reduced' or 'Engine Unavailable'; Message 'Shift to Park' when already in park; Battery charge indicator reading 0 miles despite full charge; 'Not able to Charge' message; Gas engine running at extremely high RPM to compensate; Intermittent behavior cycling over weeks
Codes mentioned: U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, U2624
Repairs/costs cited: BECM replacement cost $2,000–$5,000 depending on dealer and whether warranty/special coverage applies. GM issued Technical Service Bulletin 18-NA-261 (2018) and Special Coverage Bulletin N232432680 covering free replacement for 2016–2018 Volts under 150,000 miles for 10 years; however, many CARB-compliant vehicles (roughly 67% of 2016–2018 production) are excluded despite identical symptoms and components.
Recalls/TSBs owners mention: GM issued TSB 18-NA-261 (2018) and Special Coverage N232432680 (March 2024). Coverage appears limited; CARB-compliant VINs and some non-CARB VINs excluded despite meeting mileage and year criteria. Owners report being denied coverage despite matching all stated eligibility requirements. Some dealers claim to apply BECM updates rather than full replacement; issues recur same day.
EGR Valve Failure (Electrical Short)
The EGR valve shorts internally or fails, blowing Fuse 3. This fuse also controls the engine oil pressure control solenoid, EVAP emission purge solenoid valve, coolant thermostat heater, and oxygen sensor 1. Loss of these systems leaves the vehicle in reduced propulsion or unable to move and cooling significantly compromised.
When: Around 47,000–83,500 miles
Symptoms owners cite: Message 'Propulsion Power Reduced' or 'Engine Propulsion Reduced'; Engine running rough or surging; Engine temperature rising above normal; A/C stops blowing cold; cabin fogging immediately; Burning electrical smell from engine bay; Vehicle limp-mode with max ~50 mph; Fuse 3 blown; blows repeatedly after replacement
Codes mentioned: P0031, P0054, P0030, P0135, P0403, P0405, P0443, P0458, P0489, P0597, P0598, P06DA, P06DB, P0AC4
Repairs/costs cited: EGR valve replacement cost ~$1,140–$1,927 for part alone (labor separate). Parts are severely backordered; some owners report 12+ month nationwide backorder. Temporary fix: unplug EGR valve and replace fuse, but vehicle produces higher emissions.
Recalls/TSBs owners mention: No recall or special coverage identified. Owners report GM service bulletin exists acknowledging the defect; however, no extended warranty or repair assistance offered. Owners in emission-test states (e.g., Maryland, California) cannot legally disable the EGR valve.
'Shift to Park' Error (Gear Shift Position Sensor or Module Fault)
Vehicle displays 'Shift to Park' or 'Action Required: Shift to Park' error message even when the gearshift lever is already in park, preventing the vehicle from shutting off. Issue is intermittent initially, worsening over time. Vehicle cannot be turned off without repeatedly manipulating the shifter, sometimes taking 20+ minutes.
When: Intermittent onset; worsens progressively
Symptoms owners cite: Message 'Shift to Park' or 'Action Required: Shift to Park' displayed at shutdown despite lever in park; Vehicle cannot be turned off or shut down; Shifter moves but does not register park position; Requires repeated manipulation of shifter to achieve recognition; May coincide with 'Propulsion Power Reduced' or 'Engine Unavailable' messages; Intermittent pattern with no clear trigger
Codes mentioned: U2603, U2604, U2605, U2606, U2607, U2622
Repairs/costs cited: Repair mechanism unclear from narratives. Some owners report BECM replacement resolved the issue (cost $2,000–$5,000); others state no repair completed. Some dealers suggest gear-shift sensor or electronic control module replacement.
Recalls/TSBs owners mention: No recall or special coverage identified. Owners report this is a known issue on GM hybrid/electric vehicles since 2016 and widely discussed on forums; GM described as 'hush-hush' about the defect. Some narratives indicate BECM special coverage (N232432680) may address this intermittently.
High-Voltage Battery or Onboard Charging System Fault
High-voltage battery fails or charging system malfunctions, preventing the vehicle from charging and displaying battery-related error codes. Vehicle may fail to start or lose all electric propulsion capability.
When: 91,000–145,000 miles; one case at 13,000 miles
Symptoms owners cite: 'Not able to Charge' message displayed; Battery charge indicator stuck at 0 miles despite full charge state; Vehicle will not start after charging attempt fails; Onstar message: 'An issue with the Lithium-Ion Battery in your 2016 Chevrolet Volt has been detected. Please service your vehicle within 1 day.'; Charging system maintenance message on dashboard
Codes mentioned: U2603, U2604, U2605, U2606, U2618
Repairs/costs cited: High-voltage battery replacement cost approximately $8,000. BECM replacement also often recommended concurrently. Repair authorized by manufacturer in at least one case after engineer inspection.
Recalls/TSBs owners mention: In one case, manufacturer authorized battery replacement after engineer confirmation. No general recall or special coverage identified. One owner denied coverage due to salvage title.
Center Display Console Blank or Unresponsive on Startup
Instrument cluster or center display goes blank or completely unresponsive when the vehicle starts, hiding vital information (charge capacity, climate controls, trip data, EV range). Issue is intermittent and self-resolves after turning off the vehicle for a period.
When: Intermittent; one case at 5,000 miles
Symptoms owners cite: Center display or instrument cluster goes blank on startup; Display completely unresponsive to inputs; Reappears after vehicle is turned off for a period (usually 30 min–1 hour); May occur multiple times within days
Repairs/costs cited: Module reflash attempted in one case; issue recurred. One owner reports being told the vehicle shuts off when parked and battery becomes depleted if display failure occurs.
Recalls/TSBs owners mention: Dealer reflashed instrument cluster module and replaced backup camera in one case; failure recurred. No recall or special coverage identified.
Water Intrusion into X100 Connector (Forward Proximity Sensor & Ambient Temperature Sensor)
Water intrusion into the X100 (female) connector causes corrosion and shorts between pins, sending false or out-of-range voltage signals to the engine control module, triggering incorrect diagnostic codes and false sensor activations.
When: Unknown; reported once at unknown mileage
Symptoms owners cite: Forward proximity sensors randomly trigger; Ambient air temperature reading goes haywire; False brake booster trouble code
Codes mentioned: High voltage reading on ambient air temperature sensor
Repairs/costs cited: Connector thoroughly cleaned and dried, then wrapped intensively with electrical tape to prevent future moisture intrusion. No permanent fix identified.
Recalls/TSBs owners mention: No manufacturer response documented in narrative.
Fuse 3 Repeated Failure (Associated with EGR and Drivetrain Power)
Fuse 3 shorts or blows repeatedly when the engine switches between electric and gas modes, or due to EGR valve electrical fault. Fuse controls critical systems (oil pressure solenoid, coolant heater, oxygen sensor).
When: Associated with EGR valve failure; one case reports recurring issue during power-mode transitions
Symptoms owners cite: Fuse 3 shorts or blows; Loss of oil pressure control solenoid, coolant thermostat heater, EVAP purge solenoid, oxygen sensor 1 function; Vehicle enters propulsion-reduced mode or stalls; Fuse replaced, but shorts again within hours
Repairs/costs cited: Fuse can be replaced temporarily; however, underlying cause (EGR valve or BECM fault) must be addressed. Replacement cost minimal (~$10–$20 per fuse), but repeated cycling dangerous.
Recalls/TSBs owners mention: No recall or special coverage identified.
Airbag System Malfunction (Seat or Dashboard System)
Airbag system warning issued; manufacturer or dealer refuses to repair, citing unknown coverage or warranty limitations. Warning message states 'bring car to dealer within 1 day.'
When: Unknown; one case mentioned
Symptoms owners cite: Airbag system warning on driver display
Repairs/costs cited: Owner reports dealer refused to pay for repair; car remained in service department during appeal. Repair mechanism unknown.
Recalls/TSBs owners mention: Manufacturer or dealer denied coverage, reason unclear to owner.
Synthesized from 52 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
When the driver attempts to power down the car, the driver receives an error that the car must be shifted to park before turning off even though the car is in park. As a result the car may not be turned off. Repeated attempts and "playing" with the shifter may or may not resolve the problem.
Car lost power in 02/2024, was taken to dealer. Issue was not addressed properly. 12/2024 the car would not move, towed to dealer, estimate $2000 to replace becm, know issue for these vehicles.
Check engine light came on reduced propulsion warning. Took to Chevrolet dealer and they diagnosed EGR value failure while on road trip. Got home Took it to my local dealership and same diagnosed no part available and emissions warranty is good and it is covered but 2 year nationwide backorder by GM. The car only shows 47000 miles without parts I will not be able to use the vehicle after it fails…
*BECM, Main Battery issue. It is available for inspection at the dealership *Car would not start or move *At dealer, told they need to replace the main battery and BECM *Noticed the Engine warning light and Reduced Propulsion Power message Dealer updated the BECM, said it was ok to drive, With in the same day the same problem happened, back to dealer, now they say the entire main battery needs…
The contact owns a 2016 Chevrolet Volt. The contact stated that after starting the vehicle, the vehicle initially failed to shift into drive. After the vehicle was shifted into drive, the contact stated that while driving at an undisclosed speed, the vehicle lost significant motive power with the “Low Propulsion Power” message displayed. The contact pulled over to the shoulder of the roadway,…
Had electrical trouble with your 2016 Chevrolet Volt?
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 electrical problem on the 2016 Chevrolet Volt?
It's a documented issue but not catastrophic. 52 complaints have been filed. Repairs average $850 and most owners catch it before it causes a breakdown.
At what mileage does the electrical typically fail?
Across the 20 complaints that reported odometer mileage, most electrical failures cluster between 22,000 and 98,500 miles, with the median around 60,000. A quarter of owners report trouble before 22,000; a quarter make it past 98,500. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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/Volt.
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.