GM's instructions for the battery replacement process are linked below. Page number references in this post refer to this linked document:
Based on several owner reports on the forum, this is a collection of common issues and suggestions:
1. You can find out if you are eligible for a battery replacement if your recall number changes to x881 (2017-2019 Bolts) or x941 (2020-22 Bolts) and the status changes from "Incomplete remedy not available" to just "incomplete." You can check your recall status by entering your VIN on the Chevy recall website at:
Learn more about the Chevrolet Bolt EV & EUV recall. GM's commitment to safety insures that all Bolt owner's are able to charge & drive their EV's safely.
2. When you become eligible for a battery replacement, you can call an EV certified Chevrolet dealer to have them order the battery and then schedule the replacement. Some dealers will want you to bring in the Bolt before they order the battery. This is not part of GM's instructions, but may be part of the dealer's procedures. Sometimes, providing a photo of your Bolt's battery sticker
and your odometer mileage is sufficient. The battery may take a few days to a few weeks to arrive. Some dealerships also have customer backlogs due to limited storage space or available technicians.
This is a Google map
created by the Plug and Play EV YouTube channel for owners to note successful battery replacement experiences with dealers.
3. If you have a 2017 Bolt, the dealer will also need to order a replacement coolant hose because the connection fitting has changed (may only be for Bolts built before May 2017). The part number is 42557402 (page 3).
4. When you bring in the Bolt, make sure it is below 90% charge and has not been charged within the previous 24 hours (page 2). Otherwise, the replacement process may be delayed. The battery's state of charge is displayed on the left side of the Driver Information Center (DIC, or dashboard) as a set of 20 green bars. Each illuminated green bar represents +5% state of charge, so look for less than 18 illuminated green bars.
5. Request that the dealer charge the Bolt to 100% before contacting you for pickup (page 25). There is sometimes an error in GM's software update system that installs the incorrect software update
, limiting charge to 80%. Look for all 20 green bars to be illuminated on the DIC. The estimated range is not a reliable indicator
of the battery capacity or state of charge.
6. Sometimes, dealers do not perform the "battery pack capacity learn" step in the software procedure (page 24). That will result in the battery management system having the wrong data about the new battery's capacity, and cause strange numbers to appear for estimated range and calculated efficiency. It's possible that this will resolve itself as the battery management system receives new data as you drive, particularly after several deep discharge / full recharge cycles
7. Sometimes, dealers will not correctly perform the "vacuum fill" procedure for the battery coolant (page 20). This may result in air bubbles in the coolant system, and will result in a low coolant level in the coolant reservoir
after driving and/or DCFC charging that causes the battery coolant system to run. This can cause a warning message on the dashboard calling for immediate service.
8. There are a few reports of a metal tab / pin in the Bolt's charging port sometimes getting locked in the closed position, intermittently, after the battery replacement. This prevents the the handle of the EVSE (charger) from being fully seated, and prevents charging. The work around is to temporarily disconnect the 12V battery terminal with a 10 mm wrench. This will unlock the tab / pin, and also reset several vehicle settings back to their defaults.
Edit: There is now a software update to fix this problem, TSB 22-NA-152:
I cannot plug the charging cable into the charge port of my (post-recall-fix, 2019, LT DCFC) Bolt. The problem is the metal "latch" at the top of the charger (see photos) is stuck in position, and physically blocks the top plastic prong on the charge cable. The charge cord cannot get far...