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 ↗2019 Chevrolet Bolt EV powertrain problems
severe Owners of the 2019 Chevrolet Bolt EV have filed 13 NHTSA complaints about the powertrain 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 →
Complaints
13
Recalls
0
Avg fix
$2,500
| Model year | powertrain complaints |
|---|---|
| 2019 Bolt EV (this page) | 13 |
| 2020 Bolt EV | 11 |
| 2021 Bolt EV | 10 |
| 2022 Bolt EV | 9 |
1fire
What stands out
Of the 4 model years of Chevrolet Bolt EV we track for powertrain problems, this one carries the most owner complaints on file — 13.
No new NHTSA powertrain complaint has been filed on this vehicle in over 3 years — the issue may be aging out of the active population.
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 ↗This engineering information (EI) will assist GM to recover a small number of electric vehicle battery packs from customer-owned vehicles in the field for further engineering study and analysis.
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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report sudden loss of propulsion at highway speeds (65 mph) with no warning, forcing vehicles onto shoulders or stranding them in intersections. The high-voltage system cuts out completely; some drivers lose brakes and steering. These failures happen within days of ownership as well as at higher mileage. Error codes point to hybrid control processor failure (P0A78), and dealers have found defective wiring harnesses. GM issued technical bulletins and is aware of the issue, but some dealers refuse warranty repairs even though the defect is documented.
Separate from propulsion loss, vehicles unexpectedly shift into Park while driving, causing dangerous deceleration. Gear shift replacements haven't fixed this.
Battery-related safety issues include one confirmed vehicle fire during normal highway driving after a surge event, and another case of extreme heat buildup during Level 2 home charging (component surfaces at 113°F with 72°F ambient air). GM has recalled these vehicles twice for battery fire risk, but the original remedy didn't prevent a second recall.
After recall battery replacement and firmware updates, some vehicles develop a stuck charge port latch (multiple owners report this on forums), leaving the vehicle unchargeable. One owner notes the vehicle cannot safely be charged overnight, in a garage, or to full capacity per manufacturer guidance, making it unusable for daily driving.
Same Chevrolet Bolt EV powertrain reports on nearby years: 2020 · 2021
Failure modes owners describe
Unexpected loss of propulsion on highway
Vehicle loses all propulsion and high-voltage system power while driving at highway speeds (65 mph), forcing drivers to coast to shoulder or intersection. No warning precedes the failure.
When: Highway driving at 65 mph; one case at ~10K miles, one case on day 2 of ownership, one case at 19K miles
Symptoms owners cite: Sudden loss of propulsion without warning; Loss of high-voltage system power; Unable to accelerate or move vehicle; Loss of all power (dashboard, brakes, steering in one case); Malfunction indicator lamp after incidents
Codes mentioned: P0A78 (Hybrid Control Processor failure), Unable to Initialize Propulsion System message
Repairs/costs cited: Defective wiring harness replacement ($1567 labor + parts); transmission replacement attempted; control module replacement did not resolve issue
Recalls/TSBs owners mention: GM alert issued regarding known wiring harness defect; bulletin MC-10176614-9999 covers loss of propulsion; dealer refusing warranty repair in some cases despite bulletin
Inability to shift gears; unexpected gear shift to Park
Vehicle becomes stuck in current gear or unexpectedly shifts to Park mode while driving, sometimes accompanied by severe deceleration. Multiple occurrences reported in same vehicle.
When: While driving at 65 mph at rush hour; within first day of ownership; random occurrences
Symptoms owners cite: Unable to shift gears; shift lever unresponsive; Unexpected automatic shift to Park from L mode while driving; Severe deceleration or near-stop when gear locks; Service Vehicle Soon message; Unable to Shift message on dashboard
Codes mentioned: P0A78 (Hybrid Control Processor failure)
Repairs/costs cited: Transmission replacement recommended; control module replacement did not fix problem; new gear shift installed but vehicle not repaired
Recalls/TSBs owners mention: GM sent replacement control module; no root cause provided to owners
High-voltage battery thermal runaway and fire
Vehicle catches fire during normal driving after surging/regenerating hard; another report of fire risk observed during Level 2 charging. One vehicle burned completely after fire started on shoulder of highway.
When: During normal highway driving (case #3); during Level 2 charging at home (case #2 risk)
Symptoms owners cite: Sudden hard regeneration surge while in Drive mode; Smoke from front underbody; Full vehicle fire; Excessive heat on electronic components under hood (113°F surface, ambient 72°F); High battery temperature triggering cooling system during Level 2 charging
Repairs/costs cited: Vehicle total loss; no inspection possible after complete burn
Recalls/TSBs owners mention: GM and NHTSA characterize fires as rare manufacturing defects (2 rare defects per NHTSA); recall issued for battery fire risk; original remedy on affected vehicles did not prevent subsequent recalls
Defective wiring harness causing propulsion failure
Wiring harness defect results in complete loss of propulsion, brakes, and steering. Dealer identified as known issue with GM alert issued.
When: At 19K miles; vehicle kept in garage, never in accident
Symptoms owners cite: Complete loss of propulsion while turning in intersection; Loss of power to brakes and steering; Unable to shift into any gear; Dashboard power remains on but no propulsion available
Codes mentioned: Unable to Initialize Propulsion System message
Repairs/costs cited: $1567 total cost ($1200 labor); replacement wiring harness
Recalls/TSBs owners mention: GM aware of issue per dealer alert; GM refused to compensate owner despite known issue and vehicle only 2 months past warranty
Stuck charge port solenoid latch after battery recall service
After battery pack replacement and firmware upgrade following recall, charge port latch solenoid becomes stuck in extended position, leaving vehicle unable to accept charger (bricked state). Multiple other owners report same issue on forums.
When: After battery recall replacement and firmware upgrade
Symptoms owners cite: Charge port latch stuck in extended position; Unable to insert charger; vehicle bricked and unchargeable; Occurs post-recall service
Repairs/costs cited: No repair resolution stated by owner
Recalls/TSBs owners mention: Associated with recall battery replacement and firmware upgrade; suspected firmware bug affecting multiple vehicles
Erratic battery range display and communication after battery replacement
After recent battery replacement per recall, vehicle displays multiple critical errors including battery unable to charge. Range drops from 50% to 0 while driving, then bounces back to 110-121 mi only to drop to 0 within 15 seconds.
When: One week after February 5, 2023 battery recall replacement
Symptoms owners cite: Drivetrain malfunction message; Service high voltage battery system message; Service Vehicle Soon message; Unable to shift message; Battery range dropped from ~115 mi to 0 during driving; Unable to charge message; Battery range erratic (0 to 121 mi to 0 within seconds); OnStar detected critical engine and transmission issue
Repairs/costs cited: Vehicle at dealer for diagnosis; currently available for inspection
Recalls/TSBs owners mention: OnStar issued critical alert; vehicle underwent battery replacement per product safety recall
Abnormal ticking noise from gear shift area
Abnormal ticking noise emanates from console/gear shift area. Dealer attempted replacement of gear shift assembly over two-week period.
When: At 3,217 miles
Symptoms owners cite: Abnormal ticking noise from console/gear shift area
Repairs/costs cited: New gear shift installed; vehicle not repaired (problem persisted)
Recalls/TSBs owners mention: Manufacturer made aware but did not assist
Synthesized from 13 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
I'm experiencing the loss of propulsion covered in this bulletin. It's happened around 5 times. https://static.nhtsa.gov/odi/tsbs/2020/MC-10176614-9999.pdf The malfunction indicator lamp comes on after each incident and then clears. The problem has been confirmed by a dealer and they are refusing to repair it under either the power train or emission control systems warranty. Losing propulsion is…
Had powertrain trouble with your 2019 Chevrolet Bolt EV?
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 2019 Chevrolet Bolt EV?
It's a meaningful issue. 13 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $2,500.
At what mileage does the powertrain typically fail?
Based on the 13 complaints filed, powertrain issues most often appear around 8,677 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
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/2019/Chevrolet/Bolt EV.
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.