Model year report

2016 Chevrolet Volt: what breaks, and at what mileage

What breaks on the 2016 Chevrolet Volt

On the 2016 Chevrolet Volt, the failure owners report most often is other electrical problem, and the reports cluster around 40,000 miles. Across every failure mode on this year, half the dated reports were filed before 45,000 miles. Overall it scores 73 out of 100, high risk for a 2016.

High risk for a 2016 — 109th riskiest of the 255 2016 vehicles we can rate. 285 owner reports; fleet size estimated from this year's own recall paperwork.

What breaks on the 2016 Chevrolet Volt

Owners have reported 33 named failure modes on the 2016 Chevrolet Volt, and the three most-reported carry 36% of everything filed.

Other electrical problem leads with 43 reports, about 21,500 per 1,000 vehicles and with the middle half of reports between 21k to 90,000 miles.

Other powertrain problem follows with 31 reports, usually reported between 33k to 50,000 miles.

Control module (ECM/PCM/BCM) failure follows with 29 reports, usually reported between 84k to 90,000 miles.

By system, the reports fall mostly into electrical (75), engine (52) and transmission (40).

When these failures get reported

94 of the reports on the 2016 Chevrolet Volt came with an odometer reading, and half of those were filed before 45,000 miles.

Cumulatively, 59% by 50,000 miles, 85% by 100,000 miles and 94% by 150,000 miles of the dated reports had been filed.

The busiest stretch is between 40,000 and 50,000 miles, which alone holds 22% of the dated reports.

29% of the dated reports were filed below 36,000 miles.

In the order they tend to show up: other electrical problem around 40k, other powertrain problem around 40k and control module (ECM/PCM/BCM) failure around 90k.

Median

Other electrical problem

40k
Other powertrain problem

40k
Control module (ECM/PCM/BCM) failure

90k
Other fuel system problem

80k
No-start or intermittent start failure

143k
Other engine problem

40k
DPF, EGR or DEF system failure

60k
Overheating
no odometer readings given
—
Stalling while driving
no odometer readings given
—
Complete transmission failure

1k
Exhaust leak or fumes in the cabin

5k
Other driver assistance problem

36k

Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens

Showing the 12 most-reported failure modes of 33. The full list is in the table below.

How reports accumulate

Share of reports filed by each mileage

half by 44.5k

Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A curve that climbs early is a car with early problems, whatever its total.

Line share of reports filed by that mileage
Dashed the median reported mileage

What happens when these parts fail

Across the named modes, 6 mention a crash and 3 an injury. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.

The average severity weight across every report on this year is 3.65, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.

What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: other electrical problem at $250–$2,000, other powertrain problem at $400–$4,500, control module (ECM/PCM/BCM) failure at $700–$3,000 and other fuel system problem at $300–$2,200. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.

36% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.

Every reported failure mode

Mileage figures are percentiles of owner-reported readings. Click a column to sort.
Failure mode	System	Reports	With reading	25th	Median	75th	Per 1,000	Typical repair	Severity
Other electrical problem	electrical	43	17	21k	40k	91k	21,500.0	$250–$2,000	Moderate
Other powertrain problem	transmission	31	16	33k	40k	52k	15,500.0	$400–$4,500	High
Control module (ECM/PCM/BCM) failure	electrical	29	9	84k	90k	90k	14,500.0	$700–$3,000	High
Other fuel system problem	fuel	28	3	—	80k	—	14,000.0	$300–$2,200	High
No-start or intermittent start failure	engine	21	3	—	143k	—	10,500.0	$200–$1,800	Moderate
Other engine problem	engine	21	5	—	40k	—	10,500.0	$300–$4,000	High
DPF, EGR or DEF system failure	emissions	19	2	—	60k	—	9,500.0	$800–$5,000	High
Overheating	cooling	7	0	—	—	—	3,500.0	$400–$3,500	High
Stalling while driving	engine	5	0	—	—	—	2,500.0	$300–$2,500	Critical
Complete transmission failure	transmission	5	1	—	1k	—	2,500.0	$2,800–$8,000	Critical
Exhaust leak or fumes in the cabin	emissions	5	5	—	5k	—	2,500.0	$250–$2,000	High
Other driver assistance problem	adas	5	3	—	36k	—	2,500.0	$250–$1,800	High
Other speed control problem	adas	5	1	—	8	—	2,500.0	$250–$2,000	Critical
Shifter, linkage or stuck-in-park failure	transmission	4	3	—	31k	—	2,000.0	$250–$1,400	High
Instrument cluster or gauge failure	infotainment	4	4	—	34k	—	2,000.0	$350–$1,400	Moderate
Parking brake failure	brakes	4	0	—	—	—	2,000.0	$250–$1,300	Moderate
Other brake problem	brakes	3	3	—	63k	—	1,500.0	$300–$1,800	High
Excessive oil consumption	engine	2	2	—	60k	—	1,000.0	$900–$6,500	High
Misfire or rough idle	engine	2	0	—	—	—	1,000.0	$250–$1,600	Moderate
Thermostat failure	cooling	2	0	—	—	—	1,000.0	$250–$900	Moderate
Alternator or charging system failure	electrical	2	0	—	—	—	1,000.0	$450–$1,600	High
Infotainment screen failure	infotainment	2	2	—	55k	—	1,000.0	$400–$2,600	Low
Master cylinder or brake booster failure	brakes	2	0	—	—	—	1,000.0	$450–$2,200	Critical
Cruise control failure	adas	2	2	—	40k	—	1,000.0	$200–$1,400	High
Other steering problem	steering	2	1	—	177k	—	1,000.0	$350–$2,400	High
Other body or interior problem	body	2	1	—	40k	—	1,000.0	$200–$2,000	Moderate
Head gasket failure	engine	1	0	—	—	—	500.0	$1,400–$4,000	Critical
Water pump failure	cooling	1	0	—	—	—	500.0	$500–$2,200	High
Wiring harness or short circuit	electrical	1	1	—	48k	—	500.0	$400–$3,500	High
Seat belt or retractor failure	airbag	1	0	—	—	—	500.0	$200–$900	High
Windshield cracking	glass	1	0	—	—	—	500.0	$300–$1,600	Moderate
Other suspension problem	suspension	1	0	—	—	—	500.0	$350–$2,000	Moderate
Other seat belt problem	airbag	1	1	—	99k	—	500.0	$200–$900	High
Unclassified problem	other	21	9	40k	42k	52k	10,500.0	—	Moderate

Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.

How often, against how many were built

Scaled by an estimate of how many of these cars exist, the 2016 Chevrolet Volt draws about 142,500 per 1,000 vehicles, which puts it in the 100th percentile of complaint rates among 2016 vehicles we can rate.

That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.

The working figure is 2 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2016 vehicles, which is what the risk score uses, is far more robust than the rate itself.

What owners wrote

Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.

Recalls on the 2016 model year

NHTSA has issued 1 recall campaign covering the 2016 Chevrolet Volt, affecting an estimated 2 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.

The campaigns cover air bags:frontal. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.

Recalls also distort complaint counts. Publicity about a campaign reminds owners that complaining is possible, so reports for a recalled component often spike after the recall rather than before it.

17V621000

AIR BAGS:FRONTAL

16 vehicles 2017-10-05

Defect: General Motors LLC (GM) is recalling certain 2015-2016 GMC Canyon and Chevrolet Colorado, and 2016 Chevrolet Volt vehicles. The driver's frontal air bag may improperly inflate during second-stage deployment in the event of a high speed crash.
Consequence: An improperly inflated air bag increases the risk of injury in a crash.
Remedy: GM will notify owners, and dealers will replace the driver's frontal air bag module, free of charge. The recall began November 8, 2017. Owners may contact Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 17387.

Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.

How it ranks in the 2016 field

The score at the top of the page, placed among its peers. The zones are the same thresholds the scorer applies, read out of the scorer itself, so the picture and the band word cannot disagree.

Risk score against the rest of the 2016 field

Scores are ranked within the model year, never across years, because an older car has had longer to accumulate reports.

Left fewer and less serious reports
Right more, or worse
Marker this vehicle

How 2016 compares with the other years

High risk for a 2016 — 109th riskiest of the 255 2016 vehicles we can rate. The comparison is always within the same model year, so an older car is never penalised for having had longer to break.

Across the 9 model years of this car that carry enough reports to score, 2011 comes out best at 67 and 2018 worst at 78, with 2016 itself at 73.

If the model year is negotiable, 2011, 2014 and 2012 score lower than 2016 by a margin worth acting on. Same body, same engines, different luck — usually a supplier change or a mid-cycle fix, which the complaint data can show but never explain.

Within the 2015–2019 generation specifically, 2016 is the strongest year at 73 and 2018 the weakest at 78.

Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.

Risk score by model year, out of 100

Shorter is better. Years with too few reports to score are shown without a bar rather than as a zero, because no data is not good news.

Within the 2015-2019 generation, 2016 Chevrolet Volt scores best at 73 and 2018 Chevrolet Volt worst at 78.

What to look at before buying one

The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other electrical problem from about 21k, other powertrain problem from about 33k and control module (ECM/PCM/BCM) failure from about 84k.

On a 2016 Chevrolet Volt with more miles than that on it, the useful question to put to a seller or a mechanic is whether other electrical problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.

None of this is a diagnosis. It is a list of what other owners of the same model year reported, ordered by when they reported it, which is a good place to point an inspection and a poor place to stop.

Where these figures stop being useful

285 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.

Of those 285 reports, 94 carried an odometer reading, so the mileages here describe 33% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".

Named failure modes come from matching phrases in the complaint text, so a badly worded complaint can land in the wrong bucket. The effect washes out across hundreds of reports and does not wash out across five.

And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.

Questions this page answers

What are the most common problems with the 2016 Chevrolet Volt?

The most-reported failures are other electrical problem (43 reports, median 40,000 miles), other powertrain problem (31 reports, median 40,000 miles) and control module (ecm/pcm/bcm) failure (29 reports, median 90,000 miles). Counts come from owner complaints filed with NHTSA, which are voluntary, so they show what owners bothered to report rather than every fault that occurred.

At what mileage do 2016 Chevrolet Volt problems start?

Other electrical problem is the earliest failure mode to show up, with a median reported mileage of 40,000 miles and a quarter of reports before 20,000 miles. Across all failure modes on this year, the median report sits at 45,000 miles.

Is the 2016 Chevrolet Volt reliable?

It scores 73 out of 100 on our risk index, which is high — 109th riskiest of the 255 2016 vehicles we can rate. The score is a comparison against other 2016 vehicles, not a prediction about any individual car, and it is built from complaint rates, severity and how early failures appear.

Which year of the Chevrolet Volt is best?

Within the 2015–2019 generation, 2016 scores best at 73 out of 100 and 2018 worst at 78. Same body, same engines, different luck.

Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.

What breaks at my mileage Compare with another car

Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt 30 August 2026 Published by AtWhatMileage How every figure is computed