IllustrationMY 2004 GMC ENVOY XL SLT IS LEAKING GAS AT THE GAS TANK AND THE FILLER HOSE GAS JUST RUNS DOWN THE TANK TO THE GROUND ITS A FIRE RISK
2004 GMC Envoy Xl
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Envoy Xl years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
130–25K
2525–50K
4450–75K
2575–100K
26100–150K
12150K+
145 reports with mileage · 42 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 81 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
6 crash reports6 fire reports6 injury reports
Fuel/propulsion System complaints
8 reportsI WAS DRIVING AND MY VEHICLE ON I-985 HALL COUNTY GA. MY CHECK GAGE LIGHT CAME ON AND LESS THAN 1/2 OF A MILE IT START TO SMOKE AND BURN AS SOON AS I STOPPED TURNED OF THE IGNITION. IT BURNT TO THE GROUND FROM THE ENGINE AREA TO THE INSIDE.
VEHICLE WAS TAKEN IN FOR OIL CHANGE AND I WAS ADVISED IT HAD A CRACK AT THE NECK OF FUEL TANK. UPON FURTHER RESEARCH THERE HAS BEEN A RECALL FOR THIS VERY SAME PROBLEM ON THE SAME VEHICLE. VEHICLE WAS NEVER IN A ACCIDENT OR ANYTHING THAT WOULD CAUSE THIS.
THE GAS TANK HAS A LOSE CONNECTOR THAT LEAKS AND ALLOWS FUMES TO ESCAPE. *TR
TL* THE CONTACT OWNS A 2004 GMC ENVOY XL. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, SHE NOTICED THAT THE FUEL GAUGE READING WAS FLUCTUATING WHILE THE FUEL TANK WAS FULL. THE ENGINE THEN SUDDENLY STALLED DUE TO THE FAULTY FUEL GAUGE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED O…
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TL* THE CONTACT OWNS A 2004 GMC ENVOY XL. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, SHE NOTICED THAT THE FUEL GAUGE READING WAS FLUCTUATING WHILE THE FUEL TANK WAS FULL. THE ENGINE THEN SUDDENLY STALLED DUE TO THE FAULTY FUEL GAUGE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 101,000.
MY GMC'S SERVICE ENGINE SOON LIGHT WENT ON AND I TOOK INTO THE SHOP. THEY STATED THAT THERE IS A FUEL ISSUE FOR THE FUEL CAP AND THAT THE FUEL TANK NEEDS TO BE REPLACED BECAUSE IT LEAKS. THIS IS A MANUFACTURERS DEFECT AND THIS PART SHOULD NEVER "WEAR OUT" OVER TIME OR DUE TO THE NUMBER OF MILES DRIVEN. GMC NEEDS TO STAND BEHI…
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MY GMC'S SERVICE ENGINE SOON LIGHT WENT ON AND I TOOK INTO THE SHOP. THEY STATED THAT THERE IS A FUEL ISSUE FOR THE FUEL CAP AND THAT THE FUEL TANK NEEDS TO BE REPLACED BECAUSE IT LEAKS. THIS IS A MANUFACTURERS DEFECT AND THIS PART SHOULD NEVER "WEAR OUT" OVER TIME OR DUE TO THE NUMBER OF MILES DRIVEN. GMC NEEDS TO STAND BEHIND THEIR VEHICLE AND REPLACE THIS PART FOR FREE! *TR
DUE TO THE CHECK ENGINE LIGHT CONSTANTLY COMING ON I WAS TOLD THAT I NEEDED A NEW GAS CAP. IT WAS STATED IF THE CAP IS NOT ON PROPERLY IT AFFECTS THE EMISSION CONTROLS. I HAVE REPLACED THE GAS CAP SEVERAL TIMES NOTHING HAS CHANGED ENGINE LIGHT GOES ON AND OFF. THERE STILL HAS NOT BEEN ACCURATE JUSTIFICATION FOR THIS MATTER. VEHI…
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DUE TO THE CHECK ENGINE LIGHT CONSTANTLY COMING ON I WAS TOLD THAT I NEEDED A NEW GAS CAP. IT WAS STATED IF THE CAP IS NOT ON PROPERLY IT AFFECTS THE EMISSION CONTROLS. I HAVE REPLACED THE GAS CAP SEVERAL TIMES NOTHING HAS CHANGED ENGINE LIGHT GOES ON AND OFF. THERE STILL HAS NOT BEEN ACCURATE JUSTIFICATION FOR THIS MATTER. VEHICLE HAS FAULTY / LEAKING AIR BAGS ON THE REAR SUSPENSION. UPON RESEARCH THIS HAS BEEN A PROBLEM ON GMC VEHICLES FROM 1994 ~ 2006. WHY ARE THERE NO RECALLS? GMC ENVOY VEHICLE ARE SITTING VERY LOW DURING FREEZING TEMPERATURES. UPON STARTING THE VEHICLE IT WILL RAISE BACK UP AND LEVEL ITSELF BUT IT SHOULD NOT DROP DOWN LOW PERIOD. WEBSITES ARE FLOODED WITH COMPLAINTS. I HAVE CONTACTED GMC REGARDING ALL THESE ISSUES AND NOTHING HAS BEEN DONE. I WAS TOLD THERE WERE NO RECALLS REGARDING THESE MATTERS WHICH I DON'T UNDERSTAND. I HAVE VIEWED SO MANY COMPLAINTS ON SEVERAL WEBSITES REGARDING THESE SAME ISSUES. EXTERIOR LIGHTS~ LAMPS HAVE FAULTY SOCKETS DUE TO MOISTURE GETTING INSIDE THE LAMPS / BACK UP LAMPS. BULBS BURNING OUT CONTINUOUSLY. UNFORTUNATELY WHEN YOU TAKE YOUR VEHICLE TO A FREQUENT DEALER, MANY TIMES THEY'LL STEP OUTSIDE TO CHECK YOUR VEHICLE QUICKLY WITHOUT PUTTING YOU IN THE SYSTEM IF THEY FEEL NO SERVICE IS REQUIRED. I BELIEVE THIS MAY BE WHY THESE COMPLAINTS ARE NOT BEING ADDRESSED/ REPORTED / OR RECORDED. IT IS APPARENT THERE ARE SERIOUS PROBLEMS WITH THESE VEHICLES. SOMETHING NEEDS TO BE DONE, AND WE SHOULD NOT HAVE TO DEAL WITH REPEAT MANUFACTURER DEFECTS/HAZARDS YEAR AFTER YEAR. IT IS NOT FAIR TO US (THE CUSTOMER). THEY CAN CONTINUALLY CONTACT YOU TO TRADE IN YOUR VEHICLE OR BUY IT, BUT THEY CAN'T CONTACT YOU REGARDING DEFECTS ON THE VEHICLE. I WAS TOLD THEY ONLY NOTIFY THE ORIGINAL OWNER OF RECALLS. AGAIN THEY'LL CONTACT YOU REGARDING MARKETING AND ADVERTISING. THANK YOU IN ADVANCE FOR YOUR TIME AND CONSIDERATION. *TR
MY ENVOY HAS HAD THE CHECK ENGINE LIGHT ON FOR YEARS, AND THE SMELL OF GAS, WENT TO GMC AND THEY SAID NEED NEW GAS CAP, DIDN,T WORK, WENT TO ANOTHER CAR REPAIR NEED NEW GAS CAP, SAME THING OVER AND OVER AGAIN, EVERY MONTH ON MY ONSTAR REPORT, SAID I HAD EMISSION PROBLEMS, THEY TESTED THE CAR, LOOKS LIKE IT COULD BE YOU NEED A …
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MY ENVOY HAS HAD THE CHECK ENGINE LIGHT ON FOR YEARS, AND THE SMELL OF GAS, WENT TO GMC AND THEY SAID NEED NEW GAS CAP, DIDN,T WORK, WENT TO ANOTHER CAR REPAIR NEED NEW GAS CAP, SAME THING OVER AND OVER AGAIN, EVERY MONTH ON MY ONSTAR REPORT, SAID I HAD EMISSION PROBLEMS, THEY TESTED THE CAR, LOOKS LIKE IT COULD BE YOU NEED A NEW GAS CAP..... A FEW MONTHS AGO MY GMC WOULD NOT START, CALL AAA TO PICK UP ENVOY AND TAKE IN THE CHARLES SHOP NEAR MY HOME.... AS THE AUTO WAS BEING PUT ON THE TRAILER, I SAW GAS DRIPPING FROM THE AREA OF THE GAS TANK....WENT TO CHARLES REPAIR TO THEM ABOUT WHAT I SAW AND EXPLAINED THAT FOR YOU I HAVE BEEN TRYING TO FIND OUT WHAT WAS WRONG WITH THE GAS CAP, AND THE SMELL OF GAS... WELL THE CHECKED IT OUT AND FOUND MY GAS TANK HAD A CRACK IN IT AND I WOULD NEED A NEW GAS TANK COST AROUND $900.00, I PAID THEM FOR THE STARTING PROBLEM THAT THEY FIXED AND TOOK THE GMC HOME, I LIVE IN FLORIDA AND I WAS READING THE SUNDAY PAPER AND THERE IS AN ARTICLE, ABOUT GMC RECALLS, ABOUT HOW THE WARM WEATHER STATES HAVING A PROBLEM WITH A PLASTIC PART MIGHT CRACK AND CAUSE A FUEL LEAK..WELL THIS IS WHAT HAPPENED TO MY GMC, HOW DO I GET MY CAR REPAIRED BY GMC, WHAT CAN I DO TO GET IT FIXED, I ONLY PUT $20 TO $30 OF GAS AT A TIME ,IN THE CAR BECAUSE I DON'T WANT GAS LEAKING AND MIGHT CAUSE A FIRE. HELP ME PLEASE. *TR
Official recalls
104V527000 · Exterior Lighting:brake Lights
Nov 1, 2004
ON CERTAIN SPORT UTILITY VEHICLES, VIBRATION AND HEAT MAY CAUSE THE TAIL LAMP/STOP LAMP BULB TO LOOSEN IN ITS SOCKET. IF THIS OCCURS, THE BULB MAY FLICKER AND EVENTUALLY BECOME INOPERATIVE.
Consequence & remedy
Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE TAIL LAMP/STOP LAMP ASSEMBLIES, AND IF NECESSARY, REPLACE THEM. THE RECALL BEGAN ON NOVEMBER 22, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438, OLDSMOBILE AT 1-800-630-6537, BUICK AT 1-866-608-8080, OR GMC AT 1-866-996-9463.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4RQ17002 · Loss Of Headlights
Opened Apr 24, 2017 · Closed Mar 29, 2021
Status: closed (inferred from source dates) · Exterior Lighting:headlights
The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by General Motors adequately addressed any unreasonable risk to motor vehicle safety in the subject vehicles concerning the headlights and the HDM that controls them.Under normal electrical load and environmental conditions, the HDM can overheat inside the Underhood Electrical Center (UEC). This can cause the module to fail and result in a simultaneous loss of both low beam headlights and both daytime running lights (DRLs), often with no warning or prior detectability to the driver. This failure can be intermittent or permanent. No other exterior lights are affected. High beams, turn signals, brake lights, and reverse lights are still operational.General Motors addressed this issue with 2 recalls (14V755 & 15V519) and a special coverage program (N172091910). In view of the recalls and special coverage program implemented by GM and the vehicle high beams continuing to operate, ODI has tentatively concluded that the actions taken by GM mitigate any unreasonable risk to safety posed by HDM failure in the subject vehicles.Accordingly, the investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take additional action if warranted by new circumstances.The ODI reports cited above are available for review online at NHTSA.gov under the identification numbers in the attached document.
EA07009 · Fuel Pump Module Leaks Gasoline
Opened Jul 10, 2007 · Closed Aug 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:delivery:fuel Pump
DURING THE COURSE OF THIS EA INVESTIGATION, ODI OBSERVED THAT THE MAJORITY OF THE COMPLAINTS (88%) AND WARRANTY CLAIMS (94%) WERE REPORTED FOR VEHICLES THAT ARE REGISTERED FOR USE IN THE SALT BELT REGION OF THE US.THIS AREA INCLUDES 20 STATES IN THE NORTHEAST, MID ATLANTIC AND THE MIDWEST REGIONS AND THE DISTRICT OF COLUMBIA.CONSUMERS IN THE SALT BELT REGION REPORTED TO ODI THAT THEY COULD SMELL FUEL VAPORS IN THEIR VEHICLES WHILE DRIVING.UPON FURTHER EXAMINATION OF THEIR VEHICLES, THEY DISCOVERED THAT FUEL VAPORS WERE COMING OUT OF THE TOP OF THE FUEL TANK. THIS CONDITION IS CAUSED BY CORROSION OF THE RETURN AND SENDER LINES OF THE FUEL PUMP MODULE.WATER AND ROAD SALT COLLECT ON TOP OF THE FUEL PUMP LEADING TO SMALL PINHOLES APPEARING ON THE FUEL LINES.FUEL MAY LEAK AND COLLECT ON TOP OF THE MODULE AND/OR SPILL ONTO THE GROUND.THE DATA EVALUATED UNDER THIS INVESTIGATION REFLECT A RELATIVELY LOW FREQUENCY OF OCCURRENCE THAT LARGELY ARISES IN SALT BELT STATES.GM HAS EXTENDED THE WARRANTY ON THE SUBJECT COMPONENT TO TEN YEARS OR 120,000 MILES.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME; ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION SELECT DOCUMENT SEARCH.
PE05006 · Turn Signal Failures
Opened Feb 4, 2005 · Closed May 6, 2005
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal; Exterior Lighting:turn Signal:flasher Unit; Exterior Lighting:turn Signal:switch
BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (3)
Exterior Lighting:turn Signal:flasher Unit
BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
Exterior Lighting:turn Signal
BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
Exterior Lighting:turn Signal:switch
BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
EA04021 · Brake Lamp Failure
Opened Aug 3, 2004 · Closed Nov 4, 2004
Status: closed (inferred from source dates) · Exterior Lighting:brake Lights
GM STATES THAT SOME BRAKE/TAIL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO MALFUNCTIONING BRAKE/TAIL LAMP SOCKETS.ON MARCH 2, 2004, GM INITIATED A 6-YEAR/72,000 MILE SPECIAL POLICY FOR 989,487 SUBJECT VEHICLES TO INSPECT AND REPLACE THE REAR BRAKE/TAIL LAMP BULB SOCKET ASSEMBLIES.ON APRIL 4, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-032) BASED ON CONSUMER COMPLAINTS ALLEGING BRAKE LIGHTS NOT OPERATING WHEN THE BRAKE PEDAL IS DEPRESSED.ON AUGUST 3, 2004 ODI UPGRADED PE04-032 TO AN ENGINEERING ANALYSIS (EA04-021).BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V527) COVERING SUBJECT VEHICLES THAT WERE NOT ALREADY REPAIRED UNDER GM'S SPECIAL POLICY.MY 2004 SUBJECT VEHICLES BUILT AFTER AUGUST 8, 2003 CONTAIN IMPROVED BRAKE LAMP ASSEMBLIES AND ARE NOT INCLUDED IN THE RECALL.GM DEALERS WILL INSTALL THE IMPROVED BRAKE LAMP ASSEMBLY ON SUBJECT VEHICLES BUILT ON AUGUST 8, 2003 AND EARLIER.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.