My Chevy Bolt Has a Mysterious Popcorn-Popping Sound From the Front Suspension That Even Mechanics Can't Diagnose What's Wrong

You know that moment when your car makes a weird noise and your brain goes, “Eh, probably nothing” until it makes the sound again, and again, and now you’re driving in paranoia, turning down the radio just to hear it better?

That’s exactly what happened to one Chevy Bolt owner, and the sound in question? A weird, unpredictable popcorn-popping noise coming from the front suspension. It’s the kind of problem that’s not dangerous (yet), not constant (of course), and just mysterious enough to drive you absolutely nuts.

Enter Matt and the Bolt That Goes Pop

While scrolling through the “Chevy Bolt EV and EUV Owners Group” on Facebook, I came across a post by Matt Hill, who summed up his ongoing suspension mystery like this: “So my 2017 has been making a sort of popcorn popping sound on the driver-side front when going over some bumps, but not all. It’s been doing it for a while. I took it to a mechanic, they put it on the lift, took the cowl off, tightened the top bolt, and really couldn’t find anything loose or worn. They are suspecting something with the strut, but would have to order directly from GM. But those come unloaded, and they don’t have a spring compressor. At $160 each, I’d need to replace both, plus 3 hours of labor and an alignment. I hate to spend almost $1,000 on a 'that might be the issue.' Does anyone have any other ideas?”

That last line hit me hard, “I hate to spend almost $1,000 on a 'that might be the issue.'” Been there, Matt.

The Bolt Community Comes to the Rescue

Of course, the Bolt community didn’t leave him hanging. Several owners jumped into the comments with real-world advice.

Swiftopher offered a layered take: “If your ball joints and sway bar link are good, I’d be looking at the strut mount, just like them. You can swap the mount if you want to save, but since you’re paying a mechanic, I’d just swap all the parts so you’re not paying labor twice (if it was and needs a strut). They can rent a spring compressor from any auto parts store. I’d be concerned if they are even qualified, that they don’t have that tool already, very common and cheap to buy.”

Then Dorrington cut straight to the point: “If your mechanic doesn’t own a spring compressor, you should be looking for a new mechanic. That’s basic shop equipment.”

They're not wrong. If you're going to diagnose suspension issues professionally, you probably need a spring compressor, that's like a barista without a coffee grinder.

What Could Be Causing the “Popcorn Popping”?

So what exactly is going on under Matt’s Bolt? Suspension noises can be tricky, especially when they’re intermittent. But here’s a breakdown of the most likely suspects:

• Strut Mounts: One of the most common culprits. Worn strut mounts can make a popping or creaking noise, especially when the front end compresses over bumps.
• Struts Themselves: After several years, especially in states with rough roads or harsh winters, struts can start to give out. They might not be leaking, but internal damage can cause knocking or popping.
• Sway Bar End Links: These little guys are often forgotten but crucial. If the bushings wear out or the link loosens, it can cause random clunks and pops.
• Ball Joints: Worn lower ball joints can make metallic popping sounds that are easy to mistake for a strut issue.
• Steering Rack/Intermediate Shaft: On some Bolts, the steering shaft U-joint rubs against the floorboard carpeting, seriously, and it makes a clicking or popping noise when turning.

And let’s not forget the good ol’ fractured front driveshaft anti-click washer, which has shown up in TSBs for some 2017–2019 Bolts.

I’ve Seen This Before, In More Ways Than One

Honestly, this whole situation reminded me of how easy it is for even experienced Bolt owners to get blindsided by weird mechanical issues, especially when you’re still trying to figure out who actually knows how to fix these cars.

I’ve been through the same rollercoaster. In fact, discovering a unique sense of freedom in my electric journey as I embrace the unconventional experience of owning a Chevy Bolt was one of those moments when I realized that the quietness of an EV means you hear every creak, every pop, and every whisper of wear and tear.

And the lesson? Even when you’re in love with your EV, it’ll test you.

My Take on This Popcorn-Saga

Here’s the thing: if your shop doesn’t have the basic tools to work on a strut assembly, that’s a red flag. Not because you need high-end tools to work on a Bolt, but because these cars are different enough that you want someone who’s dialed into how they behave. It's like how one-pedal driving in a Chevy Bolt can be super rewarding until something like rusted brakes sneak up on you.

And this popcorn noise? It’s more than just annoying, it’s a sign something’s off, and the sooner it’s fixed, the less likely it’ll evolve into a bigger issue.

Other Owners Have Dealt With This Too

If Matt’s story sounds familiar, it’s because plenty of Bolt drivers have run into similar weird suspension quirks. From windshield washer fluid being the biggest expense after two years of Bolt EUV ownership to owners dealing with transitions and growing pains in the EV era, the little things can end up being the most frustrating.

And if you’re just getting into this world, you might want to start with my first impressions of the 2020 Chevy Bolt EV, or why buying the 2022 Bolt EUV might be a smarter move than the regular Bolt.

Because sometimes, you don’t really get these cars until you live with one. And then it starts making popcorn sounds.

What Can You Do If This Happens to You?

1. Get a Second Opinion: If a mechanic isn’t sure and wants $1,000 for a “maybe,” it’s time to call another shop.
2. Ask for a Proper Diagnosis: A suspension noise can almost always be traced. It just takes time, a test drive, and the right tools.
3. Start with the Strut Mounts: If you’re on a budget, this is usually the cheapest point of failure and could be replaced first.
4. Don’t Ignore It: Even if it’s not dangerous now, you don’t want that noise turning into a snapped strut or failed mount down the line.

Final Thoughts

In the EV world, we’re often talking about batteries, charging, range, and tech. But let’s not forget the bolts, bushings, struts, and squeaks that make up the actual car underneath all that innovation.

Sometimes, the biggest headaches come from the smallest pops.

What About You?

1. Have you ever chased a weird noise in your EV, and what did it end up being?
2. Do you trust your local mechanic to work on your Bolt, or have you had better chance at the dealership?

Drop your experience in the comments, I’d love to hear your popcorn story.

Narek Hareyan is a young automotive journalist with experience in a golf cart dealership and an interest in the automotive industry. Follow Narek on X for daily news coverage about cars.

Image source: Grok.