Here’s How Much A Chevrolet Bolt Replacement Battery Costs

JUN 10 2017 BY MARK KANE 78

2017 Chevrolet Bolt EV

Chevrolet Bolt EV is equipped with one of the biggest battery packs among EVs (at least without a Tesla badge on the front) – a 60 kWh unit that provides 238 miles of range.

Chevrolet Bolt EV battery pack

The battery is covered by a 8 years/100,000 miles warranty in event of failure.

As in case of many other EVs, there is the possibility to solve potential problems (fault or degradation over time) with the replacement of a new whole pack, or individual modules.

According to Fred Ligouri of Chevrolet Communications who send info to GreenCarReports, the battery pack replacement (the worst case scenario) costs $15,734.29.   And naturally if you aren’t keen to pay dealer MSRP, a pack can easily be procured for less (Google is your friend). 

The part number is: 24285978.

Fred Ligouri stressed that so far there was not a single Chevrolet Volt pack replacement under warranty, which should increase peace of mind of Bolt owners – although the chemistry found in the older Volts is not the same as in the Bolt EV.

“The current list price of a Bolt EV HV battery pack is $15,734.29 and the part number is 24285978.”

A shot of the Bolt EV’s battery pack from a pre-release test drive we attended in California (InsideEVs/George B)

“The Bolt EV battery is covered by the electric-car propulsion warranty (see specifics below) and Bolt EV customers shouldn’t expect to pay parts costs for warrantied repairs.

In [almost seven] years of Volt sales we have yet to replace a single battery pack under warranty for general capacity degradation, and many owners are still reporting they enjoy the same range capability they had when they purchased the car.

Whole battery-pack replacement is also largely mitigated by the design, manufacturing technique, dealer diagnostic, and repair tools included to support the manufacture, sale, and service needs of the Bolt EV, meaning individual modules can be replaced should it be required.

In addition to the 3-year/36,000-mile Bumper-to-Bumper Coverage, Chevrolet warrants certain components for each Bolt EV for 8 years or 100,000 miles (160, 000 kilometers), whichever comes first, from the original in-service date of the vehicle … for repairs to the specific electric propulsion components of the vehicle.”

Chevrolet Bolt EV 60 kWh NMC battery

Chevrolet Bolt EV battery finding a home!

Chevrolet Bolt EV 60 kWh Battery

GM’s family of batteries: Left to right: a first generation Volt, a second generation Volt, and a Spark EV, and a 60 kWh Bolt EV pack (Photo by Jeffrey Sauger for General Motors)


source: GreenCarReports

Categories: Chevrolet

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78 Comments on "Here’s How Much A Chevrolet Bolt Replacement Battery Costs"

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should increase pace of mind of Bolt owners

Since I can count 6, and extrapolate to 10 Modules, I would say a single Module (about 6.2 kWh) could (Should?) cost then about $1,500 or so! So – 2 of those modules would be quite enough for popping in my Firefly EV Conversion for a 12+ kWh Battery!

zzzzzzzzzzzzzzzzzzzz’s comment farther below (for $11,674.84 plus Haz Mat shipping) means it could be even less!

SparkEV battery costs $18.5K. It used to be $22K a year ago, so it’s a huge improvement.

When I asked the dealer about a year ago, they told me it would cost $35K to replace SparkEV battery if out of warranty. Not sure how much labor cost will be for Bolt, but if it’s like SparkEV, it could be $13K, which brings to total $24K for battery replacement out of warranty. That’s a lot cheaper than SparkEV battery.

That’s called disincentive pricing or dealer mark-up. I highly doubt it costs that much and you shouldn’t ask a dealership, you should go the route this person did and find it out from the manufacturer directly. Or, for that price, buy a Tesla Model III when the time comes, if you’re tired of the dealership run-around.

A battery will last much more then 10 years. And after that it is still valuable. If they do not give you at least $5000 for your old battery keep it. You can use it as a Powerwall.
The price for larger batteries will drop a lot the next few years.

It’s not clear if the battery keeps deteriorating or if there’s a cut-off point where it dies. Based on laptop experience, there’s a point when it simply dies. If that point is about 50%, that’s about 10 to 15 years of SparkEV battery.

Tesla and Bolt batteries may outlast the car (ie, bearings, interior, etc), but probably not for today’s 100 mile-ish range BEV (ie, less than 40 kWh).

Yeah, li-ion batteries are said to have a shelf life, or “calendar life”. I haven’t seen any report to indicate that any modern production EV has had its battery pack reach a point at which it dies suddenly due to shelf life, so hopefully the shelf life will outlast the expected life of the car.

I don’t know much about what causes li-ion batteries to die because of calendar life, but there is some info on that here:

Quoting you a price more than the sales price of the car is middle finger pricing.

Either that, or they want SparkEV off the road. Since GM cannot crush them like they did with EV1, one way to do that is to way overprice the spare parts (eg. Battery) so that people will crush SparkEV themselves.

I’m afraid most SparkEV will go the way of EV1, no need for GM to spend a single dime in getting them off of customer’s hands. And based on my findings (see my blog post), most of them will be gone by about year 10 to year 13.

should increase peace of mind

How can I shoe horn one of these GM Bolt packs into my 24kWh Nissan Leaf? ⚡️

Well, I’d be happy to make the Spark EV Battery work for my Electric Firefly EV Conversion, even if that included getting the Spark EV Motor & Controller, Throttle, and Instruments!

Ooops, I thought I was replying to this. See my response above regarding SparkEV bits.

Strap the battery to the roof, then get to work on hacking the firmware to recognize it. Easy!

Can someone tell me why Nissan and GM inverter/motor casings are so huge compared to Teslas?
Thanks in advance.

Tesla show their cars with only battery and electric Motor.

The picture of the Bolt in the article above has:
Battery, electric Motor, Inverter, climate components, heating elements, ventilation for cooling, cables, box for window-wipe water, …

The Tesla would look similar if you ever look under the hood and not at the showroom model.

And also very significantly the radiator.

Tesla usually shows their chassis without the radiator. This has the radiator included and radiators are of very significant size.

Bull, Tesla also shows AC and so on.
Teslas design is smarter and more elegant.

No, Tesla doesn’t show theirs with the AC system in place. He’s referring to photos like this:

comment image

GM shows their car with the entire A/C system in place including the radiator. Tesla usually shows no accessory systems at all, once in a while they show it with the A/C compressor on there but nothing more.

So what’s the point of talking about replacing a battery in an EV in 8 years with today’s pricing ? How about use 8 year ago pricing lol

Well, you can buy this today

…just off the top of my head, a 60 kWh battery pack for $15,734.29 (cheaper still if you don’t buy at dealer MSRP as GM is mentioning here) seems like a pretty good deal for those who are handy and looking for a badass home energy storage solution, or DIY project.

Yep. Would make a great core to an EV hot rod project. I suspect someone will and I can’t wait to see the pictures!

Yes a old battery with 40 kW left in about 10 years time I like 3 Powerwalls that is 3 x $ 5.000.00 value.

Great comments

Here it is for $11,674.84 plus Haz Mat shipping if you wish to buy 😉
At $200/kWh it doesn’t look expensive really.


Assuming the pack makes it 8 years+, this would mean highway capable BEV’s can compete where there’s expensive (i.e. $4.00+) gasoline ,… .

If they can get the upfront cost down, GM should be able to sell Opel Ampera E’s like hotcakes into the ‘expensive gas’ european market.

I read over on TMC, the battery may actually be 64 kWh. So may be slightly cheaper per kW.

So, since the battery can be bought for around $12,000 that works out to $200 per kwh. But, this is also why I tend to think that a strong PHEV is a better solution right now. You could put a 20 KW battery pack in a car for $4000 (and I’m sure cheaper than that for the manufacturer) and get 60-ish miles of range from that, which would be a great EV on most days, and a gas engine for the rest of the time.

Yeah, but then you have to maintain the ICE side, just like a regular ICE car. Nuisance.

Not sure what you’re talking about.. My Volt is 1.5 years old and I’ve never done any maintenance on it… except wiper fluid, but I’d have to do that on an electric too.

Duh its 1.5 years old if you have to do any major maintenance on a brand new car before hundred thousand miles there’s something wrong with the car now let’s talk about 200,000 miles or 300,000 miles

Yeah, it’s going to be a real bummer when David has to get an engine rebuild in 2065…

How many gas miles so far, D?

Chris, other than the early Leafs, I think the first Gen of electric cars are going to last a LONG time. The Volt, the Teslas and the later Leafs seem to be over engineered, i.e. overbuilt for durability. The Teslas may not be as reliable as the Volt and the later Leafs, but they are solid cars. And look at the typical Volt/Leaf/Tesla you see driving by you. Notice anything? They are almost all well cared for. Sit in one, or look in the window of one when they are charging. Don’t touch the car, just look in it. LOL! Electric car buyers are taking very good care of these cars. Or the vast majority of them seem to be, so far. So combine cars that were overbuilt for sturdiness, and then add good care and you end up with cars that will easily last 200k to 300k miles. And they may only need one new or refurb pack to last that long. I think the car companies know that, and that is why only Tesla is really pushing electric cars. Flip side of the coin, I wonder it the Gen II Volt reliability problems are GM building planned obsolescence… Read more »

This is so true, the only thing really needed is some aftermarket battery packs to upgrade the early Leafs. The rest of the car is nearly immortal, nothing really to wear out. I think this scares the OEMs to death, and certainly makes the dealership model less profitable as parts and maintenance is where they make most of their money.

Though I agree PHEV makes more sense for most people today, you can’t just scale a Bolt battery down. The PHEV duty cycle is much harsher, as a result PHEV batteries tend to cost more per kWh.

keep in mind the $200 per KWh includes the aftermarket markup. GM pays much less for these batteries.

“But, this is also why I tend to think that a strong PHEV is a better solution right now.”

I agree that a 30 kWh battery/120 mile plug in hybrid would be the perfect car. It can handle the extreme 100+ mile per day commutes we see today and eliminate the need for every making an on the road one hour battery stop.

A nice small AWD hatchback that can hold the 30 kWh battery, lots of cargo, do the work commute during the week on EV only and then up to the mountains or the shore on weekends loaded with bikes, kayaks, boat gear with no range worries…and doing most of that emissions free also.

GM put the 60 kwh battery into a Tahoe, or Suburban along with an engine as WORKHORSE is doing, and sell an 120 mile AER Tahoe or Silverado.

Or for an (E)xtended Escalade, put in 2 for 120 kwh BEV.

One of each is my ideal setup. A PHEV SUV for road trips and a sporty BEV sedan for 75% of the regular miles.

One car isn’t an option for our family anyway.

Looking like Model 3 and who knows what right now. Explorer Energi might be the best option announced so far. A third row of seats is handy when family is visiting. And unfortunately my wife has vetoed minivans, specifically Pacifica Hybrid.

She is already asking if she would be driving the Model 3 when I have to travel. I am worried I will lose it before I get it, after 5 years of waiting.

so we know who wears the trousers/pants in your family :-))

The pecking order in my house is 2 year old daughter -> wife -> cat #1 -> cat #2 -> me.

Well played, Josh!

Josh, you need a dog. Or a black cat; I find black cats to behave like dogs (ie, under human) than other types of cats.

I will bet these are only available to Bolt owners, as a replacement. If not, several EV salvage companies, are not going to be happy.

$15,000 is a reasonable price for the batter pack. With 238 miles, the Bolt is at the low end of range, a 20% battery degradation (10-15 years of above average car use) would be a good security blanket.

In 10-15 years that it might be needed, that price will likely drop to $8,000 dollars.

GM is offering batter degradation warranty which Tesla does not offer so that is another bonus point for the Bolt.

Price is about right, I don’t recall Tesla publishing their replacement prices.

Production price seems to be around $125/kwh….replacement cost is anyone’s guess.

The point is you don’t guess, they publish the prices.

In the past, for the Volt anyway, these prices have assumed a core return of an existing battery.

So the prices shown here may be a bit misleading if someone wants to just buy a battery outright without returning an old one.

Tesla does warranty their battery. The only problem is they don’t tell you what the line is. 8 years, unlimited miles.

Does anyone know:

1. How much of the BMS (if any) is included in the PN 24285978?

2. A guesstimate of how many hours of labor to R&R PN 24285978?

/is there a lot of “surgery” involved in un-wiring and wiring in the replacement pack …. or is more plug and play?

“guesstimate” is not a word. I believe you’re looking for an estimate.

an estimate based on a mixture of guesswork and calculation.
form an estimate of based on guesswork and calculation:
“the task is to guesstimate the total vote”

an estimate based on a mixture of guesswork and calculation.
form an estimate of based on guesswork and calculation.
“the task is to guesstimate the total vote”

Pedantic AND uninformed!

The definitions given could all just as easily apply to the word “estimate”, if they didn’t already include the word itself. I’m not saying that”guesstimate” isn’t something that people say; all I’m saying is that it’s something that mainly said by people who mistakenly think that that range of meaning isn’t already covered by the words “guess” and “estimate”. But fine, if our definition of a “word” is something that you can find in a dictionary, you win. It’s there. I’d just rather it weren’t. We don’t need it.

So basically because you hadn’t heard the word before or you just don’t like it we shouldn’t use it. Got it.

Guesstimate has been in use for decades. It is not exactly synonymous with estimate in that it is less likely to be as close to the actual value as an estimate would since it is based on more guesswork and less on calculation. It is closer to the actual value than a guess, however.

You are, of course, entitled to your opinion.

But the word “guesstimate” — and as other replies have already shown, it is indeed a word — is in sufficiently common use that it seems people find a use for it, even if you think they don’t.

Personally I use the word “guesstimate” to mean an estimate that’s not based much on research or actual figures, but more on experience and common sense.

Others may of course use the word differently.

BTW — a phrase you’ll see on many lists of oxymorons is “accurate estimate”. 😉

What the covfefe?!


It’s a little misleading to say no Volt Battery has been replaced under warranty. His actual statement says none have been replaced for general capacity degradation.

Don’t get me wrong, the Volt batteries are rock solid. But, some have been replaced under warranty due to internal failures. That includes full battery replacements, which were required before the dealers could replace individual modules themselves.

CCIE said:

“His actual statement says none have been replaced for general capacity degradation.”


I’ve seen that claim before, that no Volt battery has ever been replaced under warranty, and I always suspected that was very unlikely to be true. Nothing against GM, and the Volt (at least the Volt 1.0) is said to be very well engineered, but in the real world sometimes things go wrong no matter how well designed and built a complex device is.

Finagle’s law: The perversity of the Universe tends towards a maximum.

So the battery does indeed cost GM less than $200/kWh pack level then. That is good to know, then my previous estimate that GM should make a healthy gross profit on the Bolt EV makes sense.

I agree they should be able to, even though I suspect they are not. And I suspect the reason is because they were anticipating a small volume of sales so they outsourced almost everything, which usually costs more than building and designing in-house. I suspect they do not have the economies of scale to really sell the vehicle at a profit. I often wonder about the Volt too. I suspect their cost on the battery pack for that vehicle is probably $3,000 to $4,000 which means they should easily be able to pull a profit considering Toyota had to spend that much on Prius batteries in the early days and they managed to pull a profit.

Per GM, the gen 2 Volt is profitable. Also, it took Toyota 17 years to finally make a profit on the Prius.

Yes they need to produce more cars to dilute the R&D costs but it’s very important that the gross margin is (significantly) positive, otherwise there’s no point of making the product at all, outside of indirect benefits such as ZEV credits or so.

Also of note from gmpartsdirect
A Bolt inverter is about 1k
A Bolt charger is about 1k
And a Spark EV motor is about 2k as the Bolt motor is not listed…

These are substanly cheaper than DIY aftermarket EV parts for conversions and are most likely a much higher quality as they are made by teir 1 supliers…

I’ve ‘guesstimated’ for some time that an everyday EV (like the Bolt) should have a retail cost of no more than about $15,000 sans battery.

So with a 60kwh battery, looks like the Bolt ought to MSRP for around $27,000 before any tax credits are applied.

There is no doubt in my mind that GM can sell the Bolt profitably at well under $30k. Right now they are milking the federal rebates by selling it at $37.5k. And they get CARB credits.

GM knows how to build cars cheaply, and they’ve been doing that for a very long time.

Curious, What are you basing your estimate on?
Note that brand-new engines for mainstream compact cars (nothing sporty or exotic) can be bought at $2000 or so retail, not including installation. That added to your $15K number means there should be lot of $17K cars… There aren’t that many.

I think the actual answer is that the not-incl.-battery cost of an BEV on average is much higher, because the manufacturing volumes of any given model are tiny os it’s hard to amortize the initial development. Also, drivetrain is only one component; the others (steering, suspension, braking, safety, HVAC, low-voltage electrical, chassis, body, interior, seats, infotainment, computers) are all present and don’t cost inherently less for a BEV than for an ICE car.

Based off of your ‘$2,000 engine = Ice drive train’ assumption, …I’d say you weren’t very ‘curious’ at all.

I’ve suspected this for some time. All the home-built battery systems strike me as not as well-engineered. Never seen one with temperature management, cascade failure resistance, etc. This is why I’ve been hesitant to dabble in that space.

Hi Nada – do you know the price or specs of the BOLT ev APC (Auxiliary Power Converter) – in other words, the ‘alternator replacement’ that takes 300 volts in and makes 14 dc out.

Clarkson Cote tells me the gen1 VOLTECS had somewhere north of 140 amperes. Is the BOLT ev similiar? ALso, how much is it to replace it?

What’s a Tesla 60S battery pack cost?

Cost or price? That’s an important difference.

It was maybe a year ago that some Tesla spokesman let it slip that their pack-level costs were less than $180/kWh. Some people have interpreted Elon’s claims about Gigafactory battery cells to indicate a cost for Tesla of 35% lower, which would indicate less than $117/kWh for packs from the Gigafactory. But even if Elon’s bragging was just comparing the price of Panasonic’s cells in 2012 (when the Model S debuted) to Gigafactory cell costs, we can be pretty sure that Tesla’s costs are now less than $180/kWh.

Of course, Tesla’s price to you is going to be more than their cost.

Oh, the S60. Well now, is that the original Model S60, or the new S60 that is really an S75 with the pack electronically limited to 60 kWh?

If it’s the latter, well of course Tesla still has to put ~75 kWh worth of batteries into it, so the electronic limitation to 60 kWh doesn’t affect the cost.

And of course, back in 2012 when Tesla first started making the Model S, battery costs were greater than they are today. Even ignoring the price drop in cells from the Gigafactory, battery cell prices have been dropping at about 7-1/2% per year.

I haven’t seen any direct cost comparisons on pack-level costs (not surprising, as that info is treated as a trade secret by EV makers), but various passing remarks in various articles over the years lead me to think that pack-level costs have dropped faster than battery cell costs. That shouldn’t be surprising, as the cost of assembling the packs is subject to economy of scale. So as more and more EVs are made, the cost to assemble a pack keeps dropping.

I read some Tesla owner swapped out his 60 for an 85 battery…..said list price for a 60 battery was $37k. Though that was 4 years ago.
Wondering what battery costs are now.

I looked this up at a few online parts sites. Funny, but no mention of core price. I can’t believe that they wouldn’t have a core on this. Very odd. I can’t believe that a used battery pack would have zero value.

Which of course brings up the question of what the price of rebuilt battery packs would be. Lots of companies have been rebuilding Prius packs for years at a fraction of the cost of new.

Probably just way too early for stuff like that.

I am looking at a 2017 Bolt that has had the battery replaced; would the battery pack still carry the 100,000 Warranty?