NHTSA complaint: 2022 CHEVROLET BOLT EV — SUSPENSION
While driving at a low speed (approx. 5â10 mph), the front passenger-side lower ball joint suffered a catastrophic structural shear without warning. This caused the wheel assembly to collapse outward and the CV axle to pull out of the transmission. The failure caused a complete loss of steering control, veering the vehicle into a curb. Physical evidence (outward axle pull and high-side rim scratches) indicates the mechanical failure preceded the impact. This occurred at only 38,155 miles on a 2022 Chevrolet Bolt EV. Outward Dislocation: Photos show the CV axle pulled OUT of the transmission and the wheel leaning OUT (positive camber). A curb impact would push these components IN. This proves the wheel fell away from the car first. Pre-Impact Grinding: The interior barrel of the rim and the brake dust shield show heavy rotational grinding and metal-on-metal scoring. This confirms the suspension collapsed while the wheel was still spinning at speed, prior to the car coming to a stop. Structural Shear: The lower ball joint stud suffered a complete transverse shear. High-resolution photos of the broken stud face show distinct "beach marks" (concentric rings), which are the physical fingerprint of a slow-growing metal fatigue crack rather than a sudden impact fracture. Rim Damage Profile: Deep gouges are located on the flat face of the wheel spokes rather than the outer lip. This confirms the wheel was already at an extreme tilt (collapsed) when it made contact with the curb
National Highway Traffic Safety Administration — Office of Defects Investigation