NHTSA Complaint #11576323 — 2018 CHEVROLET VOLT

Main Issue: Ongoing issue with stuck caliper causing the pads and wheels to overheat increasing the tire pressure to dangerous levels. The regenerative braking system is actually very effective in slowing the car when driven in L mode. If driven smartly, driver rarely have to use a lot of force using the physical brakes and rotors. Three times now, I have had issues where the front calipers were seized and the brakes were stuck causing the wheels to have visible smoke, odors and extreme temps. Perhaps they are not being used as much as normal brakes but service was done at the dealership on both cases, only to have the issue return within a year on a low mileage car. Looking at online forums, this appears to be a common issue with the Volt. Often the High Pressure Accumulator (HPA) is not properly reset during a brake job. [XXX] I have had other non EV cars with regular brakes that worked fine for > 50k miles before service, so there is clearly an issue here. Ironically, as these brakes caliper/pistons/rotors are less used due to regen, the chance of them getting stuck seems to be an issue when they are actually engaged leading to dangerous conditions. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)