Are Chevy Volts expensive to repair?

Chevy Volts are not inherently expensive to repair compared with other plug-in hybrids, but a failed battery or major drivetrain component can push costs high, especially as the car ages and moves out of factory warranty. The Volt was discontinued after the 2019 model year, which can affect parts availability and service options. This article breaks down typical repair costs, warranty coverage, and strategies to minimize expenses for owners of these discontinued models.

How repair costs break down for the Chevy Volt

The main cost drivers for the Volt are the battery and electric drivetrain components, followed by charging hardware and routine maintenance that also applies to traditional cars. The following list covers common cost categories and typical ranges you might encounter, noting that prices vary by year, region, and whether work is done at a dealer or independent shop.

• Battery pack replacement or refurbishment: typically about $3,000 to $8,000 installed, depending on year, capacity (16 kWh vs 18.4 kWh), and whether you use a new GM pack or a remanufactured option. Availability of new packs may influence price.


• Electric drive unit and inverter repairs: commonly in the $1,500 to $4,000 range for components like the electric motor and power electronics, plus labor.


• Charging system and on-board charger repairs: roughly $500 to $2,500, depending on whether the charger or related control modules need replacement.


• Thermal management system (battery cooling) repairs: about $400 to $1,800 for items such as coolant pumps, hoses, and related cooling hardware.


• Gasoline engine and related components (oil changes, spark plugs, filters, water pump, etc.): routine maintenance costs are similar to non-hybrid vehicles—roughly $100 to $400 per service, with more expensive repairs if a major engine component fails.


• Brakes and tires: regenerative braking reduces wear but standard brake service and tire replacement remain normal costs—approximately $150 to $300 per brake service per axle; tires vary by size, typically $100 to $300 per tire.

Prices reflect typical scenarios facing Volt owners today, but exact numbers depend on vehicle year, local labor rates, and whether you use dealer or independent EV specialists. Also, the Volt’s status as a discontinued model can influence availability of fresh parts and technicians with lifecycle support.

Warranty and model-year considerations for repair costs

Because the Volt spanned two generations before being discontinued, warranty terms, part availability, and common failure modes shift by model year. The following list highlights warranty coverage and year-by-year considerations that affect repair budgeting.

• Battery warranty: Chevrolet/GM typically offers an 8-year/100,000-mile limited warranty on the Volt’s lithium-ion battery in the United States (terms can vary by region). This means substantial battery repair or replacement costs may be covered if the failure is a warranted defect.


• Model-year differences: the early Volt generations (roughly 2011–2015) used a smaller battery pack, while later models (2016–2019) upgraded to a larger pack and refined electrical systems. The bigger pack can influence both the value of a replacement and the cost if a pack is needed out of warranty.


• Part availability and service options: since production ended in 2019, new Volt-specific parts may be scarcer, pushing some repairs to aftermarket or salvage-sourced components and potentially affecting price or turnaround times.


• Recall and service campaigns: GM has implemented recalls and service campaigns on various Volt components (such as battery cooling and charging systems). Checking for active recalls on a given VIN can reduce out-of-pocket costs if you’re within the recall scope.

Practical tips to minimize repair costs

To limit expenses over the life of a Volt, consider these strategies that are particularly relevant for a discontinued model with aging components.

• Keep any battery or drivetrain repairs within the warranty window when possible; verify warranty transfer eligibility if you buy used.


• Compare dealer quotes with certified independent EV specialists who have experience with GM hybrids; labor rates and expertise can vary significantly.


• Explore remanufactured or salvaged battery packs as a cost-saving option, ensuring proper testing and compatibility with your vehicle’s electronics.


• Stay on top of preventive maintenance for the cooling system, battery cooling pump, and charging hardware to avoid expensive failures.


• Check for open recalls and service campaigns related to the battery, cooling system, or inverter; some fixes may be covered even outside standard warranties.

Because the Volt is no longer in production, verify current terms with a GM dealer or official GM service resources, as policies and pricing can change and may vary by region.

Summary

Chevy Volts are not unusually expensive to repair overall, but a failure related to the battery or key electric-drive components can lead to high out-of-pocket costs, especially if the car is out of warranty. The biggest financial risk for aging Volts is battery replacement, which is why warranty coverage, battery health, and access to qualified EV technicians matter most. For buyers and owners, focusing on preventive maintenance, exploring reputable replacement options, and understanding regional warranty terms can help manage repair expenses while keeping a Volt on the road.

What years of Chevy Volt to avoid?

The Chevy Volt years to avoid are generally the 2012, 2013, and 2017 models, primarily due to issues with the heater coolant heater, the auxiliary coolant pump, and the battery energy control module (BECM). The 2016 model also had more frequent issues, and some 2018 models need to be checked for the BECM failure if manufactured before March 2018. 
Years to avoid

• 2012 and 2013: These model years are prone to failures with the heater coolant heater and the auxiliary coolant pump, which can be expensive to repair or replace. 
• 2017: This year is notorious for BECM failures. While a recall and extended warranty are in place, the parts can be difficult to get, causing significant downtime. 
• 2016: Although the first year of the second generation, the 2016 model had a higher frequency of issues than other second-gen years. 
• 2018: Be cautious with 2018 models manufactured before March 2018, as they may have the same BECM issue that plagued the 2017 model year. 

What to look for in other years

• 2014 and 2015: These are generally reliable years, but the 2015 model was the last year of the first generation and had a smaller battery than the second-gen models that started production later in the year. 
• 2018: The 2018 model year is considered by some to be a good balance of value and reliability, especially if you can find one made after March 2018 to avoid the BECM issue. 
• 2019: The 2019 model year offers some upgrades but can be expensive due to dealer pricing. 

Is a Chevy Volt expensive to maintain?

The annual cost estimate to maintain a Chevrolet Volt is approximately $598**, depending on your service provider.

What is the life expectancy of a Chevy Volt?

Chevy Volts can last 150,000 to 250,000 miles, with some owners reporting even higher mileage, thanks to their hybrid powertrain and a battery designed for longevity. Proper maintenance is key, as the battery and other components can last for many years and miles, with some batteries showing minimal degradation even after extensive use.
 
Factors influencing the lifespan

• Battery longevity: The high-voltage battery pack is designed to last a long time, often outperforming the rest of the car. 
  • GM engineered the battery to use only a portion of its total capacity to reduce degradation, and it comes with an 8-year/100,000-mile warranty. 
  • Some owners have reported their batteries holding up well after 100,000 miles, with minimal capacity loss. 
• Maintenance: Regular maintenance is crucial for achieving a long lifespan. 
  • Keeping up with recalls and scheduled maintenance is important. 
• Engine and drivetrain: The hybrid powertrain is generally very durable. 
  • The electric motors have fewer moving parts than internal combustion engines and can last for a very long time. 
• Other components: Like any car, other components will eventually wear out. 
  • The rest of the car's electronics and mechanical parts may need repairs over time, just as in a gas-powered car. 

What to expect as the car ages

• Battery degradation: While the battery is designed to last, some degradation is normal over time and use. 
  • This may result in a decrease in electric-only range. 
  • A battery that degrades past its warranty may still function well using its gasoline backup system. 
• Potential issues: Some owners have reported specific issues, such as the "shift to park" problem or issues with the OnStar module. 
  • However, many owners report few major issues over many years of ownership. 
• Long-term running: Even if the battery's performance declines, the car can still be driven using its gasoline engine, giving it a very long operational life. 

How much does it cost to replace a Chevy Volt battery?

Replacing a Chevy Volt battery can cost anywhere from $3,000 to over $13,000, depending on the battery type (new, remanufactured, or refurbished), labor costs, and the model year of your Volt. A new battery from a dealer might cost around $9,000 plus labor, while remanufactured options from third-party providers can range from about $4,000 to $9,000, often with different warranty options. 
Factors that influence the cost

• New vs. remanufactured/refurbished: A new factory battery is the most expensive option. Remanufactured or refurbished batteries from specialized companies can offer significant savings. 
• Labor: The total cost includes professional installation. Some dealers may have high labor quotes, while other specialized shops or independent mechanics may be more affordable. 
• Model year: Older Volt models might use older technology, and the cost of the battery pack can vary by model year. 
• Warranty: Your original Chevy warranty covers battery replacement for eight years or 100,000 miles, whichever comes first. If you are out of warranty, you'll be responsible for the full cost. 

Cost examples

• New battery: A new battery from a dealer can be around $9,000, plus labor, for a total estimated cost between $11,000 and $13,000. 
• Remanufactured battery:
  • Greentec Auto offers remanufactured packs for $8,499 with a 36-month warranty or for $3,999 with an 18-month warranty, according to Greentec Auto. 
• Refurbished battery: Some sources mention that a refurbished unit from a dealer could cost around $6,000, with total replacement cost potentially between $8,000 and $10,000 with labor. 
• Individual module or cell replacement: In some cases, it may be possible to replace just a single module or cell instead of the entire battery pack, which can lower costs. A bad controller module might be a much cheaper fix, costing around $400-$700.