2019 Chevy Bolt EV Gets New Battery After 470,000 Miles for Under $3,000

A 2019 Chevrolet Bolt EV with nearly 470,000 miles on its odometer is back on the road after receiving a replacement high-voltage battery.

In a new Out of Spec Renew video, the presenter documents the installation, software programming and estimated repair costs, showing how a used battery sourced from another Bolt can extend the life of a high-mileage electric vehicle.

Original Motor Survives More Than 470,000 Miles

The Bolt EV’s previous battery was installed following Chevrolet’s high-voltage battery recall, at approximately 138,000 miles. According to the owner, that replacement pack subsequently accumulated more than 330,000 miles before the latest repair became necessary. The vehicle’s electric motor is still the original unit, although suspension components and wheel bearings have needed attention along the way.

Before the latest battery swap, the car could neither charge nor shift into Drive or Reverse. Testing identified voltage differences in two battery modules, while opening the pack revealed widespread cell swelling, according to GM Authority.

The replacement came from a 2017 Chevrolet Bolt EV and was itself a warranty replacement battery. The presenter estimated that it had accumulated between 10,000 and 15,000 miles.

Installing the pack was only part of the job. The presenter also had to reprogram two control modules, clear fault codes, bleed air from the battery cooling system and initiate a battery capacity relearn procedure. After several unsuccessful programming attempts, the process was completed.

Presenter Estimates Battery Replacement at a Few Thousand Dollars

The presenter estimated that the replacement battery cost approximately $1,800, including delivery through a discounted arrangement. For a typical customer seeking a similar battery, he estimated a price of $2,500 to $3,000.

Labor was estimated at roughly four and a half hours, costing slightly more than $800 at his shop. Vehicle-specific programming access cost $51.

Those figures put the estimated total for a comparable repair above the battery’s discounted purchase price alone. They also do not represent a universal repair quote, since battery availability, labor rates and the condition of a replacement pack can vary.

The Bolt may still need additional maintenance. The presenter identified a possible leak at the passenger-side axle seal and said the gear reduction oil should be changed. He also planned to recheck the coolant and fully charge the battery.

The repair offers a look at how replacing a high-voltage battery can keep a heavily used EV in service, even after hundreds of thousands of miles. In this case, the original electric motor remains in place while a lower-mileage replacement pack gives the 2019 Bolt EV another chance to keep going.

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