I was driving down the highway at normal speeds when I noticed the engine temperature began climbing out of the blue, and eventually the CEL light came on before the dashboard read "Propulsion Power Reduced" and eventually the engine stopped entirely and I had to coast to an area on the side of the highway where I could pull over. The battery-only part of the car was drained but there was plenty of gas in the tank, so my only way out was via the ICE. I turned the car off, waited for it to cool down, then turned it back on, only for the same issue to occur within another couple of miles of highway driving. I had to repeat this process until I was able to get to an exit and coast to a business that would let me recharge the battery enough to drive on battery-only where I could park it overnight, as I was not near my home. Eventually I had to get the car towed to a dealership, where I was told it was either an EGR valve or EGR cooler that needed replacing. After the dealership refused to provide any specifics regarding the diagnostics in writing, Chevrolet corporate informed me that it was an EGR valve that was requested and is on global backorder. This issue has not been resolved for a year now, and put me in the extremely dangerous position of losing power entirely on the highway with almost no warning, and no statements to date that would have prepared me to deal with this issue.

- Ann Arbor, MI, USA

Driving at highway speeds, check engine light came on with a warning of "reduced propulsion power" and sudden loss of speed in heavy traffic. Dealer diagnosed issue as failed EGR valve but is unable to source repair part due to frequency of failure causing years-long backorder.

- Fort Lauderdale, FL, USA

On a recent trip on a highway on our 2017 Chevy Volt, the Exhaust Gas Recirculation [EGR] failed and caused "low propulsion" errors. We ended up with a surprise bill of more than a thousand dollars to replace the EGR cooler assembly, but the problem was not resolved. The dealership then said we need to replace the EGR Valve which is estimated above $2700 plus labor. Upon checking the GM-Volt users community this is a reoccurring issue on several thousands of vehicles and the inflated price is due to the fact that GM redesigned the EGR valve to fix their original faulty design. We as consumers shouldn't be responsible for such an outrageous cost and mainly safety due to a design flow by GM. This issue should warrant a recall by GM to fix the issue once and for all.

- Cedar Falls, IA, USA

EGR valve fails causing vehicle to become disabled in traffic or stranded on a remote section of the highway. Also fails emissions testing. Chevrolet has NO REPLACEMENT parts available.

- Texarkana, TX, USA

While driving down the highway a "reduced propulsion" message appeared on the dashboard and the drive became very rough if speed changed, also the engine temperature increased but it did not overheat before we could stop. This was diagnosed as an Exhaust Gas Recirculation (EGR) Valve failure. I spoke to multiple dealers and did research online as well and this is a very common issue on this vehicle. So common that the part is impossible to get and has an eight month wait which means I cannot drive my vehicle. What component or system failed or malfunctioned, and is it available for inspection upon request" EGR Valve How was your safety or the safety of others put at risk? My car had reduced propulsion, engine temperature increased and it suddenly lost speed quickly on highway when my foot was removed from gas pedal. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No, Chevrolet is aware of this issue and say we just have to wait 8 months for the part. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear" No pre-warning a "reduced propulsion" message and a check engine light turned on at the time of the EGR valve failure.

- Maumee, OH, USA

Driving at freeway speeds when suddenly the cars propulsion power failed and I went from 75mph to 45mph with no warning and no way to accelerate. Happened multiple times even after pulling over and turning the car on and off. I was told by the dealership that was a gas engine part and that I could drive it on the electrical engine only. When attempting to drive on the electrical engine, I received a notice of engine failure and had to coast into the driveway of a dealership. I was told the engine -??could explode-?? if I continue to drive

- San Luis Obispo, CA, USA

The contact owns a 2017 Chevrolet Volt. The contact stated while her son was driving approximately 55 MPH, the vehicle lost motive power. The contact stated that the battery system became inoperable. The vehicle was towed to the local dealer, where it was diagnosed that the cells and battery needed to be replaced. The vehicle was not repaired. The dealer informed the contact that parts were on backorder. The manufacturer was contacted and opened a case. The failure mileage was approximately 69,000.

- Laguna Niguel, CA, USA

Check Engine light came on codes indicate the EGR and EGR cooling components have failed and a Propulsion Power Is Reduced message is displayed. Max speed at this point in 10 mph. This would be my second time replacing the EGR valve if the parts were available but they are not and there is no anticipated delivery date. The parts are covered in CARB states (those that have adopted California's emission rules) but not my state of NC.

- Wendell, NC, USA

The contact owns a 2017 Chevrolet Volt. The contact stated that while his daughter was driving at an undisclosed speed, the check engine warning light illuminated. The contact stated that the next morning when he attempted to start the vehicle, the vehicle made an abnormally loud sound. The contact shifted into reverse and the vehicle stalled. The vehicle was towed to the dealer. The vehicle was diagnosed with a battery malfunction. The vehicle was repaired; however, the check engine warning light remained illuminated. The contact related the failure to Manufacturer Communication Number: 10251431 (Electrical System) and TSB Number: N232422680 (Special Coverage Battery Energy Control Module Malfunction). The manufacturer was made aware of the failure and the contact was informed that the vehicle was not included. The failure mileage was approximately 142,974.

- Rowlett, TX, USA

My service engine light came on. After that happened, my engine started to get hot. It got up to 230degF, received a reduced propulsion message and wanted to shut down when going 70mph on the interstate (depended on the construction). Quick reaction on my side before the engine shut down I had "held" the battery (which i do for long trips to ensure options in event of emergencies). Meaning i still had energy in the battery that could be used to propel the vehicle. I was able to shut down the engine by unholding the battery before losing control of the vehicle due to no propulsion. The electric propulsion took over and I could get off the freeway. Conditions were: I was driving in a rain storm on a very busy interstate around Eau Claire wisconsin right around 5-6pm with lots of road construction. If I would have lost the engine and power, I would have crashed at a high rate of speed. I would have lost steering, windshield wipers and headlights. Investigation showed that fuse F03 (walk home fuse) was blown. Further investigation showed that the EGR Valve circuitry was causing this failure. After unplugging EGR valve and replacing the fuse, engine was able to run and not overheat. Plug the EGR valve back in and the fuse blows again This is a well known issue on these vehicles and has been around since 2019-2020. Lots of data and information available on this issue on the internet. To make the issue worse. No parts are available for replacing this faulty valve at the moment. Only 6 valves available in the whole USA with those promised to other customers (i Called the dealers). Additionally there are more vehicles waiting for these valves.. Vehicle goes to the shop on [XXX] for confirmation of issue and get on a waiting list for the EGR Valve. I can't believe this is allowed to continue with GM. THis needs to be fixed!!!! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Scipio, IN, USA

Had to replace EGR valve after losing power on the highway back in 2022. Lost power steering and reduced engine power while driving at highway speeds, luckily was able to get off the highway and limp the car back to my house. I almost crashed due to loosing engine power and power steering. It's appears to be a BECM issue.

- Kingsland, GA, USA

We bought the car for our son when he began to drive. We liked the idea that it was gas and electric. At the time, our son was into electric vehicles. At 44, 000 miles, 7/10/20 the car was taken to the dealership. The engine light was on at this point, the message displayed "Propulsion Power is Reduced". Once the diagnostic was done it was said that the EGR valve needed replacing. Of course, this is during the of COVID. Everything was shut down. No one is working. It is now a wait game. Prior to this our Chevy Volt has been in and out of the dealership with either recall or something else. We enjoy the car because of how it operates with gas and electric. Fast forward it is 80,000 miles now, and the car is at the dealership again. It has currently been there for almost a month. After blowing fuses it has be diagnosed as the EGR valve needs replacing again. The part is not available currently. No one seems to know when it might be available. The part cannot be purchased from our local distributor. GM is the only ones who makes it is our understanding. There is no other dealership near us that has certified technicians who can work on them. We called around and asked. We want to know what the solution is. How can this be prevented? We were over an hour away from home and no dealership was open when it went out the last time. It became worse to the point that we were stopped on the road with flashers on because it was not safe to pullover. Prayer works.

- Camilla, GA, USA

EGR Valve failed and blew fuse while I was on road. I do have the part for inspection if necessary. Part failure caused reduced propulsion in traffic on interstate. Due to GM not manufacturing part, I had to order a refurbished part from China so I could get it put in and use my vehicle after 3 months of waiting for OEM part to come in. Component has not been inspected by anyone, outside of mechanic who would have replaced it. No warnings or symptoms of issue were observed before the part failed.

- Indianapolis, IN, USA

On 2/11/23, our 2017 Chevrolet Volt displayed a check engine light and the engine started to overheat, as determined by the driver from the dash coolant temperate display, while driving down the interstate after 1 hour of driving. The car was pulled over to the side of the road and towed home. Upon inspection of the Chevy Volt later, the F03 15 amp mini-fuse(referred to as non-walk home fuse) in the main engine fuse block had blown, which had likely caused the electronically controlled thermostat to close and the engine to quickly overheat, due to lack of coolant. The reason why the F03 15 amp mini-fuse blew is because the control board for the EGR valve catastrophically failed and overloaded the fuse of this important shared electrical circuit. The electronic thermostat is part of this shared circuit, in addition to the EGR valve and possibly other important vehicle functions. I consider this cascade of electronic and engine/cooling failures to be a safety issue for the driver, in addition to being a poor design. As GM doesn't currently have any replacement EGR valves for our 2017 Chevy Volt, which includes the EGR valve control board, we are forced to disconnect the EGR valve from the vehicle and replace the F03 15 amp mini-fuse, in order to make the car drivable. This is contributing to increased vehicle emissions and reduced vehicle efficiency. In locations with emissions inspections, this EGR valve parts shortage results in the vehicle failing inspection and being made undrivable. I think the NHTSA should force GM to recall any 2nd generation Chevrolet Volt vehicles that have this defective EGR valve/control board, due to its cascading effect on the safe operation of the Volt.

- Evansville, IN, USA

On [XXX] my 2017 Chevrolet Volt with just 24,000 miles on it suddenly jerked/lost power/revved up while on the highway while using the gas engine--frightening/dangerous -- and continued to do that until I got to my destination. The error read "reduced propulsion". I was afraid of pulling off the highway for fear the car wouldn't restart and I had my 91 yr old mother in the car so we bucked along in the slow lane, the car revving fast, then losing power. It was very frightening and i proceeded with the flashers on. Took car to dealership balise in warwick ri. Tech said it was a bad EGR valve. They told me that GM would cover the repair under warranty but the part was on backorder. I opted to leave the car at the dealership hoping for the best but they said another customer had been waiting since September. They told me to take the car home, but i didnt feel the car was safe to drive. Web search reveals this is a common problem and people are waiting all over the U.S. for this part for over a year. Subsequent phone calls revealed that the part may or may not be manufactured ever again, and the dealership suggested I buy a refurbished part on ebay and have it installed at a local repair shop at my cost --- but that would null the warranty, and seemed risky to me. I asked the dealership to buy my car and they offered me $5k less than fair market value-so I declined. Opened a case at GM and they also had no answer, and offered to give me "points" to buy another GM car. Havent had use of the car since because I'm afraid to drive it with the car revving forward and at the next moment losing power. My car has been sitting in the dealer's lot for over 3 months, while I continue to pay registration, insurance and watch the value of the vehicle decline. Dangerous and GM will not buyback or rectify!!! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Westport, MA, USA

We were driving in traffic. The battery had plenty of charge. Suddenly, there was a warning notice about propulsion power problem and the car converted to gasoline mode. We continued to destination and parked. When we went to start the car, it would not start at all. Had car towed to our local Chevrolet dealership (all service done there) and that is where it is still sitting. The part needed (battery) is on back order. This occurred on July 21, 2023. Today is March 13, 2024! as of today....approaching 250 days sitting in the dealership open lot,

- Laguna Niguel, CA, USA

On Christmas day, 12/25/2023 my EGR valve failed about 60 miles from home blowing my F3 fuse and putting the car into walk home mode. Luckily after some quick searching i was able to self diagnose the EGR valve as the problem as this appears to be a frequent problem with this model of car. Lots of posts online. I replaced the fuse and unplugged the valve and was able to get my vehicle home. Jan 6th 2024 a dealer confirmed the diagnosis and confirmed it as a warranty repair. Stated since the car was drivable (ev mode) i could bring it home until the part came in since it was back ordered. It has been 66 days since the diagnosis, 13 since my safety inspection expired taking my vehicle off the road due to the check engine light on. Working with both the dealer and GM directly, neither have been able to resolve my issue. I informed all parties that my inspection would expire on 2/29/2024 and my car would no longer be drivable.

- Rochester , NY, USA

The contact owns a 2017 Chevrolet Volt. The contact stated while driving at various speeds, the vehicle lost motive power and stalled. The contact stated that the vehicle was restarted but stalled again after driving for several miles. The check engine warning light was illuminated. The vehicle was taken to the local dealer, where it was diagnosed that the EGR belt needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 90,382.

- Grapeview, WA, USA

I purchased my chevy volt on 8/17/2022. Early to mid November 2022 the check engine light appeared on the dash. It was determined the EGR valve needed to be replaced. I took the vehicle to Ferman Chevy Tampa on 11/21/2022. They replaced the EGR valve and we paid $1346.07 for the work completed. Then late December 2022 - Early January 2023 the check engine light appeared once again on the dash. It was determined that the EGR valve placed in the vehicle was a faulty part and the volt needed a new EGR valve. We waited approximately 1 month for the repair. Early November 2023 the check engine light came on once again. After inspection it was determined that once again a faulty EGR valve was placed in the vehicle. This is the 3rd time the same issue has occurred in a year. Today is Monday 2/26/2024 and volt has yet to be repaired, that is nearly 3 months! Apparently the part is not available and GM has no idea when it will be available. We were recently told possibly 2025. My husband came across some information stating that 1,600 people are currently waiting for an EGR valve for their Chevy Volt and that 2,000 have been ordered, but no one knows when they will arrive and after 3 EGR valvles going bad in one year even if the part becomes available I don't know if that will fix the problem or if it will just happen again. The car is inoperable for any long distance driving. We paid $26,431.83 for this vehicle a little over a year ago and its basically inoperable with solution from Chevy or GM. Aside from this issue I love my Chevy Volt. Its actually the 3rd one I have owned, but this is not fair to me as the consumer when they cannot reslove the issue. Thank you for you consideration in this matter.

- Apollo Beach, Hillsborough, Fl, FL, USA

Sudden failure of exhaust gas recirculation valve resulted in unexpected significant power loss on limited access highway and immediate loss of speed and acceleration. Driver was able to move to side of road with care and proceed in "limp home" mode. No warning lights activated prior to this event. Event could have been catastrophic if it occurred during heavy traffic conditions. Occupants could have been trapped in vehicle stuck in left or middle lane with no way to safely merge into oncoming high speed traffic. Car is available for inspection. GM dealer has provided the diagnosis of repair and suggested replacement of ERG valve and ERG valve cooler. This is a known defect and GM is unable to provide timely delivery of replacement parts. Waiting period of up to six months was predicted by GM dealer. Driver reports posted on internet forums reflect many Volt drivers reporting these same events and concerns.

- Sewickley, PA, USA