NHTSA Complaint #10452948 — 2011 CHEVROLET VOLT

OUR VOLT WAS LEFT OVERNIGHT TO CHARGE USING THE SUPPLIED 120V LEVEL ONE CHARGE CORD THAT COMES WITH THE VEHICLE (THEREFORE I CONSIDER IT PART OF THE VEHICLE.) IN THE MORNING THE VEHICLE WAS NOT CHARGED -- AT SOME POINT DURING THE NIGHT THE CHARGE FAILED AFTER THE BATTERY ACCUMULATED JUST 5 MILES OF ESTIMATED RANGE. THE SOCKET INTO WHICH THE CHARGE CORD HAD BEEN PLUGGED, THE RECEPTACLE OF A KILL-A-WATT CHARGE MEASURING DEVICE, WAS SCORCHED AND PARTIALLY MELTED. THERE MAY HAVE BEEN A SMALL ELECTRICAL FIRE AT THE POINT WHERE THE VOLT'S CORD PLUGGED INTO THE DEVICE, BUT IT IS IMPOSSIBLE TO SAY. THIS SEEMS TO HAVE HAPPENED BECAUSE THE STRAIN RELIEF ON THE CORD WAS TORN IN HALF AND THE WIRES IT WAS SUPPOSED TO PROTECT BECAME EXPOSED TO THE OUTSIDE AND PERHAPS TO EACH OTHER. IT IS QUITE LIKELY THAT THESE EXPOSED CHARGE CORD WIRES SHORTED AGAINST SOMETHING INSIDE THE CHARGE CORD ASSEMBLY, AND THAT SHORT CAUSED THE DAMAGE WHERE THE CORD WAS PLUGGED IN AT ITS WALL END. GUARANTY CHEVROLET TOOK POSSESSION OF THE CORD (AT GM'S REQUEST) AND ORDERED A NEW ONE UNDER WARRANTY, SO THE CORD ITSELF IS NO LONGER AVAILABLE FOR INSPECTION. I STILL HAVE THE KILL-A-WATT DEVICE, AND, DESPITE THE OBVIOUS VISIBLE DAMAGE, IT STILL WORKS. (I DON'T USE IT, THOUGH.) TO ME THE STRAIN RELIEF ON THIS CORD WAS VERY FLIMSY. THE MATERIAL SEEMED TOO SOFT AN PLIABLE TO DO VERY MUCH. THE REPLACEMENT SEEMED TO BE NO DIFFERENT APART FROM ONE ADDITIONAL FLEX SEGMENT. I WAS NOT IMPRESSED, BUT SO FAR THE FAILURE HAS NOT REPEATED. I HAVE PHOTOS IF YOU WOULD LIKE TO SEE THEM. PHOTOS OF THE OLD CORD, THE MELTED SOCKET AND THE NEW CORD. ALSO, I USED A NEW KILL-A-WATT ON THIS CAR AFTER THE INCIDENT AND ON OTHER ELECTRIC CARS WITH NO PROBLEMS. IT MAY BE TEMPTING TO BLAME THIS DEVICE, BUT IT HAS A SUFFICIENT AMP RATING AND THE PROBLEM HAPPENED ON A DAY THE STRAIN RELIEF FAILED. *TR