Remember, early Volters (and ELRers) were/are pioneers of the automotive EV revolution. Designs will improve as issues arise. The components on the BECM are wear items, such as the high voltage relays and heater module. The problem is access to these parts require dropping the entire pack. Newer designs will hopefully place these parts in more convenient location.
Maybe those relays wear out prematurely because of the incessant horn beeping that forces us to turn the car off and on fifty times a day...

 

I kind of agree with the OP. I like my Volt but it's nowhere near ready for prime time. The BECM in my 2017 failed once already and I fully expect it to fail again (hopefully while the Voltec warranty is still in effect). My EGR hasn't failed yet but I fully expect it to. I should have gotten a Prius Prime but I wanted to buy from an American manufacturer.

 

It is disappointing, but I knew going in that we were early adopters. Hopefully the lessons learned from the Volt and Bolt will result in more robust next generation EVs from GM. Repairs on some of these electric “wear” items will hopefully be more easily accomplished as well as the ability to easily replace a bad battery cell or module of cells. I will do more research into the maintainability of my next EV given what we have learned from the Volt. But all that being said, my 2013 has had no battery or VOLTEC issues yet at 95,000 miles.

 

Pictures would benefit from explanatory text for each.

My 2011 is still doing well.

 

I was curious as well so I reviewed the OP's prior posts. He explains his problem and the solution in this thread: 2012 Intermittent DTCs when charge cable connected, car...

 

Guessing, but the only visual issue that is immediately obvious is corrosion/arcing evidenced on terminal R6.

 

this pin configuration is a problem when any type of current goes thru it.mercury marine tried those small pins on relays that controlled fuel pumps and ign A voltage to injectors and such,they'd work for a couple of years then whacky things start happening.
fix was back to larger pin connections.I know first hand as my efi boat engines had the small pins.

good info OP,thanks for sharing.

 

Wow... through-hole soldering components. Haven't seen those in a while!

That looks like a typical molex connector issue. Sometimes caused by a bad crimp on the pin or socket, sometimes a bad alignment with the pin and socket, sometimes corrosion creates increased resistance at the connection point.

Looks like a day of labor to get to the board, 30 seconds with a solder iron, 30 seconds to put on some dielectric tune-up grease, and a day to get it back together.

Are there issues on the board other than pin R6?

 

look at the 3 pins and it looks like the female pin was forced apart, more than likely someone forcing the pins in crooked some how

 

so the day after i post this, i read that the bolt production gets shut down
things that make you go hmmmm
someone hit the big reset button in regards to the bolt
lets see
i work at the forum arm of the r&d department of gm

 

had to replace a whole bms at the airport becouse of a failing connector like that buried in the back
way to many suits that day