General Motors announced that battery production for the Chevy Bolt EV is once again underway. Battery production resumed on Monday, the automaker said, and outlined a course of action to “ensure that customers can safely and confidently drive, charge, and park the Chevy Bolt EV and EUV.”
Over the past twelve months, the Bolt EV has had three recalls related to battery issues that have caused combustion in some instances. During the July recall, the second related to battery problems, GM announced that “the simultaneous presence of two rare manufacturing defects in the same battery cell” caused an increased risk of battery fires. The recall affected around 69,000 cars worldwide.
GM then doubled down on the recall in late August, announcing that it had temporarily halted production of the Bolt altogether. GM spokesman Daniel Flores commented:
“We will not resume repairs or restart production until we are confident LG is producing defect-free products for us.”
As of now, manufacturing of the Bolt EV has not resumed, only the production of the battery cells that the vehicle utilizes.
The recalls set GM back around $1.8 billion so far this year and led to a widespread case of paranoia among those who saw the vehicles on the road. A parking lot in San Francisco actually prohibited Bolt EVs from parking at their facility due to the battery issues.
Now, GM has announced that production has resumed for Bolt EV batteries. Due to an updated manufacturing process and new advanced diagnostics software from GM, there is now confidence from the Detroit-based automaker that the worst of the issues are now behind them. “We’re grateful for the patience of owners and dealers as we work to advance solutions to this recall,” GM Executive VP of Global Product Development, Purchasing and Supply Chain, Doug Parks, said. “Resuming battery module production is a first step and we’ll continue to work aggressively with LG to obtain additional battery supply. In addition, we’re optimistic a new advanced diagnostic software will provide more convenience for our customers.”
The Bolt EV utilizes cells from battery supplier LG, which operates cell production plants in Holland and Michigan. Both facilities have resumed production and replacement battery modules will be shipped to dealers “as soon as mid-October,” the company said. LG has worked with GM to initiate and implement a new plan of attack that will recognize and identify defects in battery cells, providing confidence in the batteries moving forward.
How the Chevy Bolt EV became GM’s 1.8 billion dollar problem
In terms of the replacement process of the affected population, GM said it will “continue to prioritize Chevy Bolt EV and EUV customers whose batteries were manufactured during specific build timeframes where GM believes battery defects appear to be clustered. The company has established a notification process that will inform affected customers when their replacement modules will be available.” The new batteries will include an extended warranty as well: 8-year/100,000-mile limited warranty (8-year/160,000 km limited warranty in Canada).
Additionally, GM will launch a new advanced diagnostic software that will roll out within approximately 60 days. The software will detect specific abnormalities that might indicate a damaged or defective battery in either the Bolt EV or EUV, alerting customers of abnormalities. GM plans to allow owners to return to 100% state of charge once diagnostic processes are completed. For now, the company states that owners should do the following:
- Set the vehicle to a 90 percent state of charge limitation using Target Charge Level mode. Instructions on how to do this are available on chevy.com/boltevrecall. If customers are unable to successfully make these changes or do not feel comfortable making these changes, GM is asking them to visit their dealer to have these adjustments completed.
- Charge the vehicle more frequently and avoid depleting battery below approximately 70 miles (113 km) of remaining range, where possible.
- Continue to park vehicles outside immediately after charging and do not leave vehicles charging indoors overnight.
News
EVs getting cleaner more quickly than expected in Europe: study
Battery-electric vehicles are still championing emissions reductions, and a new analysis suggests they’re doing so even more quickly than previously expected.
As Europe’s electricity mix is getting cleaner, battery-electric vehicles (BEVs) are also offering a larger climate advantage than previously expected, according to the results of a new study released this week.
On Wednesday, the International Council on Clean Transportation (ICCT) released a study noting that BEVs sold today produce 73 percent fewer life-cycle greenhouse gas emissions than internal combustion engine (ICE) vehicles, even factoring in production. This figure also represents a 24-percent improvement upon the organization’s 2021 estimates for this year, meaning that BEVs are getting cleaner more quickly than expected as the continent’s renewable programs continue to grow.
The study was comprised of a comprehensive life-cycle analysis of all major powertrain types, and the results suggest that BEVs are the only widely available powertrain that can slash emissions levels enough to meet climate goals. By contrast, the study’s results suggest that other clean energy powertrains, such as hybrids and plugin hybrids, only have a marginal impact, if any, on reducing the overall climate impact of the transportation sector.
“Battery electric cars in Europe are getting cleaner faster than we expected and outperform all other technologies, including hybrids and plug-in hybrids,” says ICCT researcher Dr. Marta Negri. “This progress is largely due to the fast deployment of renewable electricity across the continent and the greater energy efficiency of battery electric cars.”
Credit: International Council on Clean Transportation (ICCT)
READ MORE ON ELECTRIC VEHICLES: Study reveals hybrids could have up to 4.9x lifetime emissions vs. BEVs
ICCT Senior Researcher Dr. Georg Bieker says he also hopes the analysis can help fight misinformation regarding BEV powertrains. For example, he notes that, while it’s true that manufacturing emissions for BEVs can be up to 40 percent higher than for ICE vehicles, this is quickly offset by an electric automobile after just around 17,000 km (~10,563 miles) of driving.
“We hope this study brings clarity to the public conversation, so that policymakers and industry leaders can make informed decisions,” Dr. Bieker says. “We’ve recently seen auto industry leaders misrepresenting the emissions math on hybrids. But life-cycle analysis is not a choose-your-own-adventure exercise.”
Additionally, the ICCT study covers emissions from both vehicle and battery production, recycling, fuel and electricity production, fuel consumption, and maintenance.
“Our study accounts for the most representative use cases and is grounded in real-world data,” Dr. Bieker adds. “Consumers deserve accurate, science-backed information.”
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Tesla executive teases plan to further electrify supply chain
One of Tesla’s top executive hints at how Tesla is further electrifying its supply chain.
A high-level Tesla executive has said the company is working to further electrify its supply chain, following a successful road test with the Semi this week.
After Tesla supplier thyssenkrupp completed a successful 5,000-mile winter trial with the Semi this week, Dan Priestley, the company’s Director of Semi Engineering, noted on X that the demonstration is a part of larger efforts to electrify more of the supply chain. The executive said that the company is already working to help suppliers like thyssenkrupp implement the Semi into their operations, particularly due to its cost savings and reliability.
Following the thyssenkrupp demo, the supply chain company has also begun integrating the Semi into its fleet, and Priestley suggests that more are still to come:
Working with our suppliers and logistics partners to electrify Tesla’s supply chain. With lower cost and higher reliability, it just makes sense. thyssenkrupp pushed the truck hard over this demo and now plans to integrate Semi into their fleet.
🚨 A Tesla Semi rolling around near Gigafactory Texas
If you remember, the Drone GOAT 🐐 @JoeTegtmeyer spotted one on factory property last week!pic.twitter.com/tvchIQar1u
— TESLARATI (@Teslarati) June 10, 2025
READ MORE ON TESLA SEMI: Tesla Full Self-Driving displays impressive collision avoidance with Semi
Tesla Semi factory nears official production as trials continue to impress
Tesla’s early Semi trials received positive results from both thyssenkrup and ArcBest’s ABF Freight this week, with the latter company logging 4,494 miles during a pilot period, and averaging 321 miles per day despite a 7,200-foot climb over Donner Pass.
The company has also been constructing a factory for volume Semi production at its Gigafactory in Nevada, and in recent weeks, the plant is looking nearly complete. Semi frames have been spotted in increasing numbers outside the facility recently, suggesting that Tesla is nearing early production on site.
The company also hired more than 1,000 workers for the Semi factory in April, while the plant is eventually expected to produce as many as 50,000 Semi units annually.
Tesla reveals Semi fleet data, shows off new feature and infrastructure plans
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Tesla Semi completes 5,000-mile winter trial with thyssenkrupp
The test covered nearly 5,000 miles in winter conditions.
thyssenkrupp Supply Chain Services has completed a three-week pilot of the Tesla Semi at one of its California logistics hubs, marking a new step in the company’s sustainability push. The test covered nearly 5,000 miles in winter conditions and focused on evaluating the electric Class 8 truck’s efficiency, transparency, and operational performance.
Tesla Semi offers efficiency gains and real-time logistics visibility
During the pilot, the Tesla Semi was used for active freight delivery, including routes over the Altamont Pass. thyssenkrupp evaluated the vehicle’s ability to reduce downtime, enhance delivery speed, and offer greater real-time supply chain visibility, the company noted in a press release.
Live diagnostics and performance monitoring allowed the logistics provider to track metrics such as speed, routes, and overall efficiency—data that supports smarter and more transparent logistics operations.
“The Tesla Semi aligns with our ongoing commitment to sustainability and operational excellence,” said Bob Denehy, Chief Commercial Officer at thyssenkrupp Supply Chain Services. “Its efficiency and diagnostic features, and low environmental impact make it a natural fit for our evolving logistics strategy.”
Pilot builds on long-term partnership with Tesla and green energy goals
A logistics partner to Tesla since 2015, thyssenkrupp Supply Chain Services was one of the first companies selected to test the Tesla Semi in a real-world setting. The trial reinforces the company’s push into renewable energy logistics and reflects its long-term goal of integrating alternative-fuel technologies across its operations.
Plans are now underway to begin adding electric Semis to its fleet as part of a wider emissions-reduction effort. The pilot is thus the latest example of how logistics providers are embracing next-generation transport technologies to meet environmental goals and enhance supply chain performance.
EVs getting cleaner more quickly than expected in Europe: study
Tesla executive teases plan to further electrify supply chain
Tesla Semi completes 5,000-mile winter trial with thyssenkrupp
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