This preliminary informational (PI) bulletin provides information to dealership personnel that may be helpful when addressing underbody component corrosion with customers.
full bulletin at NHTSA ↗2016 Chevrolet Volt powertrain problems
moderate Owners of the 2016 Chevrolet Volt have filed 51 NHTSA complaints about the powertrain, typically surfacing around 40,000 miles at roughly $2,500 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See powertrain across all vehicles →
Failure mileage
Complaints
51
Recalls
0
Avg fix
$2,500
| Model year | powertrain complaints |
|---|---|
| 2012 Volt | 20 |
| 2013 Volt | 23 |
| 2014 Volt | 4 |
| 2015 Volt | 6 |
| 2016 Volt (this page) | 51 |
| 2017 Volt | 216 |
| 2018 Volt | 82 |
| 2019 Volt | 16 |
When does it fail?
Of the 51 powertrain complaints filed for the 2016 Chevrolet Volt, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 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
Powertrain accounts for 30% of every owner complaint on file for this vehicle — the dominant problem area across 4 categories tracked.
Owners have filed 51 powertrain 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 powertrain 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 service bulletin provides information on some vehicles that may rock or move slightly forward or rearward while in Park at start up after cold soak. This condition may be accompanied by a clunk noise. This is a slight movement that is more often seen visually, rather than felt, when viewed from the outside and using the auto-start feature, if equipped.
full bulletin at NHTSA ↗GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
full bulletin at NHTSA ↗This service bulletin provides information on Driveline Clunk Noise and what is acceptable and what is considered normal operation.
full bulletin at NHTSA ↗This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report two dominant powertrain defects in the 2016 Volt. The Battery Energy Control Module (BECM) fails between 63,000 and 100,000 miles, leaving cars unable to start, charge, or move. When it fails, the vehicle displays "Shift to Park" or "Propulsion Power Reduced" warnings and will not restart; some owners are stranded on highways or on-ramps with total loss of brakes and steering. Repair costs run $2,500–$5,000+, and replacement modules are frequently backordered. GM issued extended warranty coverage (15 years, 150,000 miles) for BECM failures but applied it selectively by VIN, leaving hundreds of owners to cover the bill themselves, even those barely past the original eight-year warranty.
The second widespread issue is a shifter sensor failure: the vehicle refuses to recognize that it is in Park, displaying "Action Required: Shift to Park" even when parked. The vehicle will not power down or lock the doors, forcing owners to restart and shift repeatedly—sometimes 5–28 times—before the error clears. This defect worsens over time and becomes nearly daily. GM published a Technical Service Bulletin acknowledging the fault across multiple models but has not issued a recall, and dealerships inconsistently deny warranty coverage despite the TSB.
Owners also report uncontrolled acceleration in electric mode, complete propulsion loss while driving at highway speeds, EGR valve electronics failure with a critical parts shortage, transmission failure, and battery charging defects. Many view these as interconnected failures stemming from the BECM or related electrical control architecture.
Same Chevrolet Volt powertrain reports on nearby years: 2013 · 2017 · 2018 · 2019
Failure modes owners describe
Battery Energy Control Module (BECM) Failure
The BECM fails, preventing the vehicle from starting, charging, or shifting into gear. Owners report a 'Reduced Propulsion' warning on the dash, sudden loss of power while driving, and inability to restart. This is a known defect affecting multiple model years, and GM extended warranty coverage (N232432680, 15 years/150,000 miles) but applied it selectively, leaving many owners uncovered and facing repair costs of $2,500–$5,000+.
When: Between 63,000 and 100,000 miles; occurs as early as 63k miles for some owners, near or just past the original 8-year/100,000-mile warranty expiration for others
Symptoms owners cite: Vehicle will not start or will not remain started; Charging not available or battery will not charge; Shift to Park error message displayed; Propulsion power reduced warning message; Reduced electric range (e.g., limited to 49 miles instead of 50–60 miles); Engine light illuminated
Codes mentioned: B101D, P1E00, P1EAC, P0AFA, B3111, U3001, U2401, U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, U2624, P1FD1, P1FD2, P1FD3, P1FD4
Repairs/costs cited: BECM replacement (GM Part # 24296900); hybrid battery connectors may require cleaning or replacement; disconnect relay replacement. Repair costs cited: $2,500–$5,005.58. Dealers note parts shortages and extended lead times.
Recalls/TSBs owners mention: GM issued Special Coverage Warranty N232432680 (15 years, 150,000 miles) for BECM malfunctions in certain VINs, but denied coverage to many owners claiming the warranty is model-specific or the VIN is not included. Service bulletins exist but are internal guidance; GM has not issued a national recall. Some owners report GM refusing warranty assistance citing bumper-to-bumper warranty expiration.
Shift-to-Park Sensor/Shifter Assembly Malfunction
The vehicle fails to recognize that it is in Park position, displaying an 'Action Required: Shift to Park' error message even when the shifter is physically in Park. This prevents the vehicle from powering down and locking the doors. The defect is attributed to a faulty microswitch in the transaxle shift cable or wiring harness short in the shifter assembly. Owners report the issue worsens over time, eventually requiring 5–28+ restart-and-shift cycles to power down the vehicle.
When: Intermittent at first; becomes more frequent over time, eventually occurring on almost every power-down attempt after several months to years of ownership
Symptoms owners cite: Action Required: Shift to Park error message on dashboard while shifter is physically in Park; Vehicle will not power down despite shifter being in Park; Doors will not lock when error is displayed; Dashboard lights and interior lights remain on; Requires multiple restart/shift cycles to finally power down the vehicle; Intermittent initially, then progresses to nearly every shutdown attempt
Codes mentioned: 19-NA-206
Repairs/costs cited: Shifter cable replacement, shifter assembly replacement, wiring harness replacement, or shift-park solenoid replacement reported. Repair costs cited: $736.71–estimated few hundred dollars for parts and labor. Some owners report repairs failing to resolve the issue permanently, with the problem reoccurring within days or weeks.
Recalls/TSBs owners mention: GM published Technical Service Bulletin 19-NA-206 (Version 6, December 2020) acknowledging the issue across multiple GM vehicles (Volt, Blazer, Malibu, Traverse, Acadia). Owners report the bulletin states repairs are warranty-covered, but dealerships have inconsistently denied warranty coverage. Class action lawsuits have been filed regarding this defect in other GM models. No national recall has been issued.
Uncontrolled/Unintended Acceleration Under Electric Drive
The vehicle suddenly accelerates without driver input while in electric drive mode. Owners report pressing the accelerator lightly at cruising speed (e.g., 65 mph) triggers an abrupt acceleration (to 88+ mph), and applying the brake, regen paddle, or cruise control does not stop the acceleration immediately. A 'clack' sound from below the driver's console occurs in some instances before power returns to normal.
When: Occurs while driving at highway speeds (65–75 mph); one incident reported on a vehicle with only 1,080 miles on it
Symptoms owners cite: Sudden, unintended acceleration while in electric mode despite light accelerator input; Brake pedal, regen paddle, and cruise control do not immediately disengage acceleration; Large electrical draw from battery shown on dash during acceleration surge; Acceleration ceases only after repeated hard brake pedal presses; 'Clack' sound from below driver's console (reported in at least one case); Vehicle returns to normal operation after the incident
Repairs/costs cited: No repairs cited in narratives. Dealer investigation reportedly unable to duplicate the problem and blamed a floor mat in one instance.
Recalls/TSBs owners mention: Dealer worked with GM corporate engineers in at least one case but was unable to reproduce the issue and did not perform repairs.
Complete Propulsion Loss While Driving
The vehicle suddenly loses all power—engine, electric motor, brakes, steering, and transmission response—while actively driving, typically at highway speeds. The vehicle becomes immobile and uncontrollable on the roadway, creating an immediate safety hazard. Owners report seeing 'Propulsion Power Reduced' or 'Shift to Park' warning messages before or during the incident.
When: Occurs while driving at highway speeds (65–75 mph) with minimal warning; one instance reported just as vehicle entered an on-ramp
Symptoms owners cite: Sudden and complete loss of engine, electric motor, and transmission power; Loss of brake responsiveness and steering control; Vehicle cannot be coasted or pulled safely off the roadway; Dashboard displays 'Propulsion Power Reduced' or 'Shift to Park' message; Vehicle will not restart after shutdown; Vehicle brakes/electrical systems may remain partially functional (one owner used emergency brake to stop)
Repairs/costs cited: Replacement of BECM, transmission, and related components. One owner reported BECM and transmission replacement covered under warranty, but transmission hoses and labor not covered. Another owner required replacement of a 'battery control sensor' (likely BECM). Repair timelines extended due to parts backorders and labor delays.
Recalls/TSBs owners mention: Dealerships have performed diagnostics and repairs under warranty coverage where applicable. No specific manufacturer response documented regarding the safety hazard or recall.
EGR Valve Electronics Failure and Parts Unavailability
The EGR valve's electronic control circuit fails, causing fault codes, reduced engine power (limp mode at 5 mph), and illuminated check-engine light. When the faulty EGR valve is unplugged, the engine operates normally but the check-engine light remains permanently on. The required replacement part (initially GM Part # 12691147) is chronically backordered. After months of waiting, GM changed the part number to 19436113 and increased the price by 1,100% (from $243 to $2,642), with continued unavailability.
When: Failure occurred during normal driving; part unavailability persists for over 11 months at time of report
Symptoms owners cite: Engine warning fault light illuminated on dashboard; Dozen fault codes stored in vehicle computer; Vehicle slows to 5 mph with no throttle response; Non-Walk Home fuse blown; EGR valve electronics failure indicated; Vehicle can only be driven if EGR valve is unplugged, but check-engine light remains on continuously
Codes mentioned: Non Walk Home fuse blown
Repairs/costs cited: Replacement EGR valve required. Original part (12691147) priced at $243, replaced by GM with part 19436113 at $2,642. Parts unavailable for over 11 months due to high demand. Independent mechanic unplugged the faulty EGR valve and replaced the fuse as a temporary workaround.
Recalls/TSBs owners mention: GM changed the part number and increased the price substantially, but has not resolved the parts-shortage issue. No recall or service bulletin addressing EGR valve electronics failure was mentioned.
Transmission Failure and Post-Repair Transmission Fluid Leak
The transmission fails suddenly, causing inability to shift gears or respond to throttle input. Vehicle shakes, makes unusual noises, and switches unintentionally between electric and gas power. After replacement transmission installation, transmission fluid leaks from the transmission cooling system. Dealers cover the transmission replacement under warranty but not the replacement of transmission cooling hoses or associated labor.
When: Transmission failure occurred on a vehicle with only 1,080 miles; post-repair leak discovered the day after transmission replacement
Symptoms owners cite: Vehicle will not accelerate despite throttle input; Unable to shift out of Park; transmission does not engage any gear; Vehicle rolls backward when brake is released and car is in gear; Unusual noises and shaking from transmission area; Unintentional switching between electric and gas power; Post-repair transmission fluid leaking onto garage floor from cooling system
Repairs/costs cited: Full transmission replacement performed under warranty (cost not specified). Replacement transmission cooling hoses required but not covered under warranty; labor to install hoses also not covered. One hose arrived at time of report; vehicle not to be driven until replacement complete.
Recalls/TSBs owners mention: Warranty covered the transmission replacement but denied coverage for transmission cooling hoses and installation labor, classifying hoses as 'not part of the transmission.'
Battery Charging Failure and Intermittent No-Charge Condition
The battery refuses to charge when plugged in, displaying 'Charging is not available' on the dashboard console. This is often an early warning sign preceding BECM failure. Owners report intermittent charging issues that persist for extended periods (months to years) without diagnosis, even when demonstrated to dealership service personnel.
When: Intermittent initially, occurring over months; progresses to complete charging failure
Symptoms owners cite: Dashboard displays 'Charging is not available' message; Vehicle plugged in but refuses to accept charge; Intermittent charging failure that resolves temporarily; Reduced electric driving range (noted in some cases); Vehicle eventually fails to start after prolonged charging failure
Repairs/costs cited: Often resolved by BECM replacement or hybrid battery connector cleaning/replacement. One owner reported an internal electrical cable (described as corroded) required replacement, but the part was discarded before full diagnosis.
Recalls/TSBs owners mention: Dealerships have declined to cover intermittent charging issues under warranty in some cases, claiming inability to diagnose the fault. Special Coverage Warranty N232432680 (15 years/150,000 miles) covers BECM-related charging failures but only for select VINs.
Synthesized from 51 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 7 most recent
When parking the car after having stopped, ant error message 'shift to park' appears on the display even though the shifter was in park. This problem prevents car from being turned off.
While driving suddenly the battery power died (1/3 battery life left) and the ICE came on reving very high and check engine lights came on and vehicle slowed. Pulled over at first spot I could find and tired to restart the car. Car would not power down or restart the ice motor and the electric drive motors stopped working and vehicle would roll backwards once put into drive. Vehicle had to be…
Unable to turn off power to car with error on dashboard saying shift to park. Have to power on and off several times while moving the shifter in and out of park to get the car to turn off.
This vehicle has a shift to park message that been seen on many gm vehicles. Some of the owner sites I have been to say that this is covered under warranty. I have not been so lucky with gm. The dealer did cover 1 repair of this problem but now says I have to pay. The problem has returned and persists. A shift to park message is displayed on the dash after the car is in park and will not…
There is a “Shift to park” message on the driver information screen when attempting to shut off vehicle. I don’t know if the vehicle is still in gear and will move (forward or back) when I think it is in Park. I have not had it in for inspection/repair yet, as it is a recent occurrence that is becoming increasingly frequent. This started happening around 11/15/2021.
I had just left my house about to enter the on-ramp to Interstate 95 south when my 2016 Volt abruptly and without warning stopped. I was unable to coast or pull the car to the side of the road. I was in the middle of the lane in a dangerous place to stop a car and a dangerous place to get out of the car due to the steady traffic entering the interstate. My car would not restart and I had it towed…
Driving 72mph down I5 interstate the display notified me with a check engine light with two errors, enigne propulsion reduced and engine overheating. I pulled over to the side of the road and called a tow. This was a very traumatic event. I had my partner and my 2 year old daughter in the car.I just purchased this used vehicle from a Toyota dealer the same day. It has 63k miles on it and still…
Had powertrain 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 powertrain problem on the 2016 Chevrolet Volt?
It's a documented issue but not catastrophic. 51 complaints have been filed. Repairs average $2,500 and most owners catch it before it causes a breakdown.
At what mileage does the powertrain typically fail?
Across the 22 complaints that reported odometer mileage, most powertrain failures cluster between 30,742 and 49,061 miles, with the median around 40,000. A quarter of owners report trouble before 30,742; a quarter make it past 49,061. 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 $2,500 for powertrain 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 powertrain?
No active recalls currently cover powertrain 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.