A 2019 Chevrolet Bolt EV has traveled about 470,000 miles over seven years, surviving multiple battery issues while retaining its original electric motor. After its battery pack failed and left the car unable to drive, reverse or charge, a replacement battery brought the high-mileage EV back to life for an estimated total cost of $2,651.
A Chevrolet Bolt EV With Nearly 470,000 Miles
EV batteries gradually lose performance over time, with the rate of degradation depending on several factors. This Chevrolet Bolt EV offers an unusually high-mileage example of how a vehicle can continue operating despite significant battery wear.
The 2019 model previously underwent a recall when its odometer showed 138,000 miles. It then covered another 330,000 miles before its battery pack was replaced again.
Despite its extensive mileage, the Bolt is still running on its original electric motor. Out of Spec Renew, which posted the video documenting the vehicle, also reported that suspension components and wheel bearings had been replaced during its lifetime.
Why the Original Battery Had to Be Replaced
The old battery pack had deteriorated to the point that the Bolt could no longer shift into drive or reverse or accept a charge. An inspection of the opened pack revealed widespread swelling and low voltage, both signs that the battery needed replacement.
Battery packs are consumable components in electric vehicles because charging and discharging contribute to wear over time. Physically examining the cells requires opening the pack, making a direct inspection necessary to assess the condition of its internal components.
A Used Battery Brings the Bolt Back to Life
To get the Chevrolet Bolt EV running again, a replacement battery pack was sourced from an older 2017 model. Its mileage was estimated at between 10,000 and 15,000 miles.
Installing the replacement battery was not a simple plug-and-play process. The vehicle required software programming to recognize the new pack, and it took several attempts before the Bolt was running again.
The estimated total cost for the used battery, installation and labor was $2,651. That amount included $1,800 for the battery, $800 in labor and $51 for software programming.
For a typical customer repair, the estimated cost of the battery replacement is about $2,500 to $3,000. That figure does not account for the Bolt’s second-hand value.
More Repairs Remain After the Battery Replacement
Although the replacement battery has returned the Bolt to operation, the vehicle still needs additional work. The outstanding issues include a leaking passenger-side axle seal and a gear reduction oil change.
Given the car’s age and mileage, changing the battery coolant and fully charging the cells are also recommended steps. With nearly half a million miles behind it, the Chevrolet Bolt EV is running again, but its return to the road has not eliminated the need for further maintenance.
