2023 Chevrolet Bolt EV

Both front wheel drive shaft anti-click washers on my 2023 Bolt EV fractured at 18,269 miles. The failure caused a repeatable click/clunk from the front of the vehicle on torque application — accelerating from a full stop, from a slow roll under 5 mph, or accelerating out of a coast at about 20 mph. A Chevrolet dealer confirmed both anti-click washers were cracked (Repair Order 652900). The repair required removing both front half-shafts, replacing the washers (GM P/N 42754282) and drive shaft nuts (GM P/N 13208079), and reinstalling the axles. The noise was eliminated. This is a safety issue because GM has documented in writing that this exact failure can damage the ABS wheel speed sensor, which sits directly in-line with the washer on the outboard joint of the half shaft. GM TSB 22-NA-089 (Bolt EV) and TSB 19-NA-103 (Volt) both state the fractured washer causes "possible collateral damage to the ABS wheel speed sensor," that ABS, Traction Control, and StabiliTrak lamps may illuminate intermittently, and that those systems "may be deactivated/shut off for that ignition cycle," setting DTCs P215B and C0035-C0051. Loss of anti-lock braking and stability control is a direct safety hazard. My core concern is scope. GM acknowledged this defect in 2019 (Volt, MY2016-2019) and 2022 (Bolt EV, MY2017-2019), but capped the bulletins at model years that exclude my vehicle. My 2023 Bolt EV suffered the identical failure of the identical part, fixed by GM's identical specified procedure and part numbers. Other owners report the same failure on 2020, 2022, and 2023 Bolts. I was charged $737.34 as customer-pay. The dealer submitted a warranty claim and GM rejected it, stating a BEV has no applicable powertrain coverage for this component. I request NHTSA review whether this defect extends to later model year Bolt EV/EUV vehicles and whether a recall is warranted.

known issue with " anti click washer on Bolt EV " and resulting damage to related components can cause loss of control acceleration, stopping and major damage and cost, no warning lights or TSB other than for previous gen but same design and same defect, inspected by dealer shows broken anti click washer and damage to other components https://gmauthority.com/blog/2022/07/heres-why-your-chevy-bolt-ev-may-have-a-clicking-sound/

The vehicle suffers from severe, unresolvable electrical failures causing recurring loss of propulsion, shifting lockouts ("No Driving Conditions" / stuck in Park), complete exterior lighting failures, and loss of communication with the Restraints Control Module (RCM) and airbag impact sensors. The primary failure involves short circuits, open circuits, poor terminal contact, and thermal damage with melted, charred wiring and exposed copper in the main harness[cite: 6]. On May 25, 2026, OnStar telematics issued a critical red alert for the Regenerative Braking System[cite: 7]. All damaged components and diagnostic reports are available for inspection upon request[cite: 6, 7]. Safety risks include sudden loss of propulsion at highway speeds, total headlight and tail light loss during night driving, and potential non-deployment or malfunction of airbag restraint systems during a collision. The issues have been repeatedly reproduced and confirmed by an authorized dealership through 7 repair attempts between Sept 2024 and Apr 2025. Diagnostic steps included opening GM TAC Case 9-13634782861, consulting GM engineers, and testing 33 ground points. On Oct 28, 2024, the dealer and an insurance adjuster officially confirmed the failures are covered under GM warranty and unrelated to any accident[cite: 8]. Symptoms first appeared on Sept 10, 2024 (at 5,144 miles) with a "Waiting initialization to shift" message, blown Fuse 58, and loss of power to the ECM. Warning signs prior to subsequent failures included "Service Trans" warnings, "Reduced Propulsion" alerts, dim headlights, Check Engine Lights, SRS/Airbag warning lights, and total shifting lockouts after hitting road bumps. Despite replacing Fuse 58 (multiple times), Fuse 64, IP Fuse 7, the underhood fuse block, ECM connector terminals, headlamp assemblies, the RCM module, and multiple airbag impact sensors, the underlying electrical instability remains unresolved.

While driving a 2023 Chevrolet Bolt during a turn maneuver, one of the two bolts (nearest the driver) holding the lower control arm (to the vehicle on the front driver side) sheared completely. An inspection of the joint suggests a fatigue failure likely due to inadequate factory assembly clamping force (pretension). Because the joint lacked the required factory torque, the joint interface slipped under normal operational loads, shifting cyclic shear and bending forces directly onto the bolt threads and shank—loads the fastener was not designed to carry alone—resulting in a fatigue fracture. The sudden failure of a primary front suspension control arm fastener while the vehicle is in motion is a safety hazard. It causes steering instability and risks a loss of vehicle control. The problem was confirmed and repaired by an independent service center/mechanic who replaced the control arm sub-assembly. The sub-assembly has been retained and is available for inspection upon request. The vehicle and failed component have not yet been inspected by the manufacturer, police, or insurance representatives. There were no warning lamps, dashboard messages. We had noticed the tire was rubbing on the wheel well during certain maneuvers for months beforehand, but we thought the wheel well liner was sagging. In hindsight this was due to the control arm not being firmly held by the bolt. When the bolt sheared my wife reported hearing a loud pop, the vehicle was still drivable but unstable, as soon as we realized something was severely wrong we took it slowly to the nearest mechanic where they repaired the problem.

Steering rack failure, does not return to center most of the time. Every once in a while it will. Loud clunking in steering, started right around 36k mile warranty expiration, but I didnt know what it was so did not report it right away.

Vehicle infotainment system on 2023 Chevrolet Bolt completely stopped functioning in May of May of 2026. Screen/radio/bluetooth and associated components had no functionality, including backup camera, safety warning features, etc. Dealership confirmed that the system needed replacement entirely and was non-functional. Vehicle was not inspected by any other parties but it was confirmed by the dealership that this is a "common issue" for Chevrolet vehicles, even newer models. There were no warnings prior to the issue - the system simply did not work one day and never functioned again.

The steering has become harder to turn and will not return to center after turning a corner. When driving the steering wheel will stay in the position you have turned it to. I feel like this is dangerous and a safety risk especially at highway speeds. I have taken it to my local Chevrolet dealership and they said the rack and pinion steering is bad and needs to be replaced. $2365 parts and labor and realignment. The vehicle had 50058 miles on it when I noticed it. It now has approx. 52,500 miles on it. There were no warning lamps or safety messages.

I bought my 2023 Bolt EV new on Dec 2024. Around Jan 2025 I start hearing clicking behind the steering wheel when I turn to make parking maneuvers. By April 2025 the clicking is loud and a common occurrence. The steering no longer returns to center and it is noticeably hard to turn the steering wheel. I brought it to the dealership and was repaired under factory warranty for being a faulty part. The issue, which was a leak causing the steering rack to bind, was fixed. See the attached Chevrolet dealership documentation for further details. I have not noticed any further issues after driving for month after repairs were done.

Without any warning or physical impact, the central infotainment screen completely blanked out and suffered an irreversible hardware failure. This screen acts as the mandatory display terminal for the vehicle's rear-visibility backup camera, as well as the audio generation module for the vehicle's driver alerts. Because of this component failure, the vehicle is in direct non-compliance with Federal Motor Vehicle Safety Standards (FMVSS): 1.FMVSS 111 (Rear Visibility): The vehicle completely fails to display a rear-view image when shifted into reverse, creating an immediate blind-spot hazard for pedestrians. 2. FMVSS 101 (Controls and Displays): All critical audible safety alerts, pedestrian alerts, and driver warning chimes have been entirely silenced. The manufacturer (General Motors) and the authorized franchise dealership (F.H. Dailey Chevrolet) have acknowledged the failure and have the part on backorder, but refuse to fully cover the safety restoration under warranty or provide a temporary loaner vehicle. This forces the primary driver, a [XXX] senior citizen, to choose between total isolation or operating a hazardous, federally non-compliant vehicle. This appears to be a systemic manufacturing or design defect inherently tied to the internal HMI module architecture on the late-model Chevrolet Bolt EV platform, rather than individual wear and tear. A formal investigation is requested to mandate a safety recall and enforce full manufacturer accountability. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The steering wheel does not return to center after turning while driving the car (unlike every other car). It has been reproduced by an independent service center. There are no error codes or warnings. This is a continuous problem that always happens and makes steering the vehicle more difficult.