2011 Chevrolet Volt

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

The subject vehicles, which employ emerging technology, are range-extended electric vehicles that utilize a high voltage (HV) battery to provide energy for propulsion. The HV battery is lithium-ion based technology that has a nominal full charge of 390 VDC, a 16 kWh capacity, and a control system that incorporates liquid (antifreeze) cooling and various electronic devices (control modules, sensors, wiring, etc) to monitor and manage the HV battery. The HV battery, portions of the cooling system, and the control system are contained within a common enclosure.During an NCAP oblique side pole impact test conducted by NHTSA in May 2011, the pole struck and deformed the sill plate under the driver's door at a location where there is a structural member. The lateral member displaced inward, pierced the HV battery enclosure and battery, and caused a battery coolant leak. Thereafter, the Agency conducted a rollover test (the rollover test consists of four 90-degree rotate-and-hold movements about the vehicle's longitudinal axis). In that test, the HV battery and electronics were exposed to coolant that leaked as a result of the crash. The vehicle fire that occurred three weeks later and the additional testing NHTSA conducted are discussed in a report titled 2011 Chevrolet Volt Battery Fire Incident Report a copy of which is available in the public file. The report indicates that intrusion induced coolant leakage, and subsequent rollover that saturates electronic components, were the only test conditions which resulted in a subject vehicle HV battery fire.GM announced its intention to conduct a free-of-charge customer satisfaction campaign (CSP) on the subject vehicles on January 5, 2012. The action affects 14,735 vehicles produced prior to December 21, 2011. The CSP addresses three areas related to the issue under investigation. The first involves a modification/strengthening of the structure of the vehicle in the area where battery intrusion occurred in the May 2011 test. The second involves adding a sensor that detects excessive HV battery coolant loss, and control system software that then alerts the driver and prevents recharging of the HV battery. When the battery cannot be recharged, it will be depleted to a lower energy state as the vehicle continues to operate on the internal combustion engine. Lastly, a tamper-proofing device will be added to the system to prevent consumers from adding coolant. GM discusses these revisions in its response to an Information Request (IR) issued by NHTSA, noting that vehicles produced in calendar year 2012 and later will be manufactured to this condition.In December 2011, and at the same test facility, NHTSA repeated the May 2011 side impact test using a model year 2012 Volt modified to the structural condition described in the CSP. The test did not produce intrusion of the HV battery, a coolant leakage, or a fire (see test 7611, available at www.nhtsa.gov/Research/Databases+and+Software). In its IR response, GM describes four (4) additional side impact tests of modified subject vehicles it recently conducted using various build configurations and impact speeds (including higher speeds). GM reports that none produced HV battery intrusion, coolant leakage, or a fire.As noted in the complaint counts above, ODI has not identified a crash occurring in consumer's use of the vehicle that has resulted in a vehicle fire, or produced coolant leakage. ODI notes that side impact crashes with pole-like structures, such as would strike the sill plate, occur fairly infrequently, and such crashes with rollovers are even less frequent. A defect trend has not been identified at this time, and further investi

The contact owns a 2011 Chevrolet Volt. The contact stated that water was accumulating inside the driver's side taillight assembly. The contact stated that the water caused a short circuit in the taillight, and the passenger’s side turn signal became inoperable. The contact had taken the vehicle to an independent mechanic where it was diagnosed, and determined that the wiring harness for the driver's side taillight assembly needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 97,000.

NHTSA ID

11694484

Incident

Aug 20, 2025

Mileage

97,000 mi

I was stopped at a red light with my foot on the brake. When the light turned green, I released the brake and the car suddenly accelerated forward on its own, without me touching the accelerator. As soon as the car surged forward, I immediately pressed the brake pedal hard to stop it but instead of slowing down, the car continued to accelerate. It felt like pressing the brake was making it worse. The car was totally out of my control. The vehicle collided with tow truck and even after the impact, the engine was still revving as if it was trying to keep going. I had to shut the car off to stop it completely. There were no warning lights or error messages before or during the malfunction. The front end of my car was damaged in the crash. No one was injured, but the malfunction could have easily caused serious harm or death. This was not user error it was a terrifying mechanical and electronic failure. The car accelerated on its own and the brakes failed or possibly triggered more acceleration. I have never experienced anything like this. After looking online, I found other Volt owners reporting similar problems involving brake assist failure, unintended acceleration, and stuck revving. This looks like a serious pattern that deserves urgent attention. I’m asking the National Highway Traffic Safety Administration (NHTSA) and General Motors to immediately investigate this issue. I want to know if there are any recalls, technical service bulletins (TSBs), or known defects related to brake failure or unintended acceleration in the 2011 Chevy Volt. Please contact me with next steps. This is a major safety risk that could easily result in fatalities if not addressed.

NHTSA ID

11678156

Incident

Jul 30, 2025

Driver display is blank (no speed, gear position, odometer, gas tank, etc), with the exception of some warning icons like tire pressure and passenger seat belt status. Does no return after turning off power.

NHTSA ID

11585428

Incident

Apr 21, 2024

'11 Chevy Volt hybrid was daily driver of 100+ miles, multiple trips both highway and city for last 2 1/2 months. Breaks and rotors have been replaced all the way around, fresh oil changes as needed and filters. Warning on dash "Service High Voltage Charging System", ”Service Airbag" and check engine light have been on since I've owned it (Oct. 23). When plug car in it doesn't charge, but the EV charges while driving. Car generally switches back and forth from EV to ICE without issues. No other issues have been noted. 1/18/24 Start car and drive all day for work. Total of 129 miles between 22 trips. Last trip car sat for 30 minutes after running deliveries all day. Started as normal, turned off at gas station, filled tank with premium, restarted and drive to freeway. Drove 20 miles, pulled over to text, put car in park. 5 mins later took out of park and car wouldn't move. Inside had complete power, radio, windows, ect. Only noticable difference was car would get no acceleration, power steering went out, and heat started blowing cooler air. Absolutely no warning and car just cuts off engines. Thankfully I was parked safe. Towed home, replaced 12v. Started and drove no problem on 1/19/24. No new warnings or anything different. Started up 1/20/24 drove 7 miles and the engines cut off in the middle of a main road while accelerating, once again no warning. Luckily got into turn lane before almost getting hit. Still not sure what's wrong with car. Same codes. No battery warning or loss of power indication at all. Just up and cuts off. This is very very dangerous and needs to be looked into please. When my volt died today the truck behind me had to slam on his brakes and came inches from hitting me. If this would've happen on the freeway, I'd likely been hit.

NHTSA ID

11566740

Incident

Jan 20, 2024

The car quit running when my wife was driving the car when the mileage range went down to 4 miles range remaining. The car was towed to the local Chevrolet dealership who charged over $1,000 to reset the electronics so car would run. I was advised that if battery range was run down to a low mileage range that car would quit running again and that it would have to be towed back to the dealership for the electronics to be reset. I was concerned about liability if anyone drove car and it stopped on highway. It was clear to me that the only way out of potential liability, associated with the car stopping on the highway was to sell the car for salvage. I purchased this Chevrolet Volt Premier new. It was never in a collision or damaged in any way. The car was sold for with approximately 81,000 miles for $2,013.

NHTSA ID

11562597

Incident

Feb 17, 2023

The contact owns a 2011 Chevrolet Volt. The contact stated that while driving at an undisclosed speed, the contact heard an abnormal whining sound coming from the engine compartment. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 90,000.

NHTSA ID

11544532

Incident

Aug 25, 2023

Mileage

90,000 mi

The contact owns a 2011 Chevrolet Volt. The contact stated that while driving at 35 MPH, the defroster failed to operate as needed. The vehicle was taken to the dealer, and the dealer replaced the heating system module; however, the failure recurred. The vehicle was taken back to the dealer, but the dealer was unable to duplicate the failure. The failure mileage was unknown.

NHTSA ID

11497799

Incident

Jan 15, 2020

Several times over the 2 years I have owned this vehicle while driving an almost complete loss of braking occurs with a service notice for the ABS system. If you turn off the ignition and restart it the braking works fine. I am in the process of having the Electronic Brake Control Module - GM (84070136) and the Brake Pressure Modulator Valve - GM (23283683) replaced. i believe that there is a design flaw in this system in that a problem of the ABS should not eliminating the ability to stop the vehicle. This is costing me $3500, but the point is that loss of braking is a serious safety issue and should be addressed by the manufacturer. Thank you.

NHTSA ID

11469570

Incident

Jun 16, 2022

This preliminary information communicates information about how to determine if a wheel and tires size change is available.

This Preliminary information communicates the steps on how to save a GDS2 Session Log and upload to a Technical Assistance Case in CX Connect.

This preliminary information advises a dealer on how to email GDS2 session logs into Technical Assistance.

This preliminary information advises a dealer on how to email GDS2 session logs into Technical Assistance.

This Preliminary Information communication provides information to the technician about vehicles that have had multiple repair attempts that are being performed on customer’s vehicles that exhibit vibration conditions without utilizing the support of General Motors Technical Assistance Center. If valid vibration frequency or Road Force Variation data has been collected and a repair attempt does not correct the customer complaint, contact General Motors Technical Assistance Center for further support. For any vehicles that remains unrepaired after being at the dealer for three days or more and a related bulletin or PI is not found, contact General Motors Technical Assistance Center for further support.

This engineering informational bulletin provides process for a GM engineering study on curtain Takata Airbag Steering Wheel Modules and needs the used Takata airbags to be returned to GM.