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2004 GMC Envoy

Owner reports · Recalls · Investigations

More warning signs than most Envoy years

Owner complaints for the 2004 GMC Envoy are substantially higher than the model-year median of 22.

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When problems were reported

Mileage at the reported incident

288 reports with mileage · 79 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 164 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 39 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

25 crash reports11 fire reports22 injury reports

Exterior Lighting complaints

39 reports
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103,000 miles · Jul 21, 2010
Exterior Lighting

2004 ENVOY: REAR BRAKE LIGHTS AND PARKING LIGHTS HAVE FAILED FREQUENTLY AND NEEDED REPLACEMENT 6 TIMES IN 6 MONTHS. BRAKE LIGHT FAILURE IS A SAFETY HAZARD. IT MAY RESULT IN AN ACCIDENT. I SAW A RECALL ON NHTSA WEBSITE ABOUT THIS PROBLEM. TOOK CAR AND NHTSA PAPERWORK TO GM DEALER . DEALER SAID RECALL WAS FOR VEHICLES BEFORE…

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2004 ENVOY: REAR BRAKE LIGHTS AND PARKING LIGHTS HAVE FAILED FREQUENTLY AND NEEDED REPLACEMENT 6 TIMES IN 6 MONTHS. BRAKE LIGHT FAILURE IS A SAFETY HAZARD. IT MAY RESULT IN AN ACCIDENT. I SAW A RECALL ON NHTSA WEBSITE ABOUT THIS PROBLEM. TOOK CAR AND NHTSA PAPERWORK TO GM DEALER . DEALER SAID RECALL WAS FOR VEHICLES BEFORE AND AFTER MINE. THIS CONFLICTS WITH NHTSA CAMPAIGN NUMBER #04V527000. *TR

NHTSA ODI #10344471

50,000 miles · Jan 7, 2010
Electrical SystemEngine And Engine CoolingExterior Lighting

TL*THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT OBSERVED WHILE DRIVING THE SPEEDOMETER DISPLAYED AN INACCURATE READING REGARDLESS OF THE SPEED BEING TRAVELED. IN ADDITION, THERE WAS A MALFUNCTION WITH THE HEADLIGHTS REMAINING "ON" WHEN DEACTIVATED. THE FAILURE OCCURRED INTERMITTENT. THE FAN CLUTCH FAILED UNEXPECTEDLY. THE …

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TL*THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT OBSERVED WHILE DRIVING THE SPEEDOMETER DISPLAYED AN INACCURATE READING REGARDLESS OF THE SPEED BEING TRAVELED. IN ADDITION, THERE WAS A MALFUNCTION WITH THE HEADLIGHTS REMAINING "ON" WHEN DEACTIVATED. THE FAILURE OCCURRED INTERMITTENT. THE FAN CLUTCH FAILED UNEXPECTEDLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION. THE FAN CLUTCH WAS REPLACED. THE CONTACT HAD CONCERN OF THE SAFETY RISK INVOLVED. THE FAILURE MILEAGE WAS 50,000. THE CURRENT MILEAGE WAS 57,000.

NHTSA ODI #10298542

79,000 miles · Nov 29, 2009
Exterior Lighting

2004 GMC ENVOY SLE - FREQUENT RECURRING PROBLEM WITH HEADLIGHT FAILURE. HEADLIGHTS WILL TURN OFF WITHOUT NOTICE. CHECKED FUSES, CONNECTIONS AND WIRES. HAVE TAKEN TO LOCAL GMC DEALERSHIP (BECKON MASTON) FOR REPAIR HOWEVER DEALERSHIP UNABLE TO DIAGNOSE. VEHICLE IS COMPLETELY OEM, PLEASE ADVISE. *TR

NHTSA ODI #10293926

72,000 miles · Oct 21, 2009
Exterior Lighting

WINDSHIELD WIPERS WHEN TURNED, EVEN IF THE MIST OR WASH IS SELECTED WILL NOT TURN OFF WITHOUT SHUTTING THE VEHICLE OFF FOR APPROX. 15 MINUTES ALSO BOTH HEAD LOW BEAM HEAD LIGHTS WILL NOT TURN ON WITH OR WITHOUT THE SWITCH. *TR

NHTSA ODI #10289289

89,673 miles · Jul 31, 2009
Exterior Lighting

MY HEADLIGHTS GOES OUT WHILE IM DRIVING AND I WAS JUST TRYING TO FIND OUT ABOUT GMC RECALLS THEY HAD A RECALL ON THE HEAD LIGHTS SHINING IN THE WRONG DIRECTIONS BUT MINE CUTS OFF SEVERAL TIMES I HAVE TO PULL TO THE SIDE OF THE ROAD/HIGHWAY TO WAIT FOR THEM TO COME ON AGAIN I HAVE RUN OFF THE ROAD ONCE. *TR

NHTSA ODI #10278982

10,000 miles · May 17, 2009
Exterior Lighting

2004 GMC ENVOY 4X4. *TR

NHTSA ODI #10268963

Mileage unknown · Apr 5, 2009
Electrical SystemExterior Lighting

WHEN TRAVELING DOWN THE ROAD AND PUTTING ON THE BRAKES THE HEADLIGHTS AND DASH LIGHTS FLICKER. THE FLICKERING IS SO MUCH THAT IS LOOKS LIKE WE ARE FLASHING OTHER CARS. *TR

NHTSA ODI #10264199

4,500 miles · Nov 4, 2008
Exterior LightingCrash

2004 GMC ENVOY HEADLIGHTS WOULD PERIODICALLY DIMM AND GO OFF DURING BREAKING. WITHOUT WARNING HEADLIGHTS FAILED WITH NO INDICATION. REPAIR AT GMC DEALER COST $130 FOR A "HDM RELAY". VERY DANGEROUS FAILURE AS NO FUSES FAILED, NO LAMPS FAILED, BUT A HIDDEN COMPONENT FAILED WHICH CAUSED ME TO GO OFF A HIGHWAY AT HIGH SPEED AT NI…

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2004 GMC ENVOY HEADLIGHTS WOULD PERIODICALLY DIMM AND GO OFF DURING BREAKING. WITHOUT WARNING HEADLIGHTS FAILED WITH NO INDICATION. REPAIR AT GMC DEALER COST $130 FOR A "HDM RELAY". VERY DANGEROUS FAILURE AS NO FUSES FAILED, NO LAMPS FAILED, BUT A HIDDEN COMPONENT FAILED WHICH CAUSED ME TO GO OFF A HIGHWAY AT HIGH SPEED AT NIGHT. *TR

NHTSA ODI #10247633

96,000 miles · Oct 16, 2008
Exterior Lighting

THE TRUCK'S DIM LIGHTS ALL OF THE SUDDEN STOP WORKING. THE BRIGHT LIGHTS COME ON, BUT THE DIM LIGHTS WILL NOT COME ON AT ALL. THE BULBS WERE CHECKED, AND THE DIMMER SWITCH. I'VE TAKEN IT TO 2 MECHANICS, AND NO ONE CAN FIND OUT WHAT'S WRONG WITH THE LIGHTS. I CAN'T GET MY TAGS RENEWED BECAUSE THE DIM LIGHTS DON'T WORK AT ALL. I'V…

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THE TRUCK'S DIM LIGHTS ALL OF THE SUDDEN STOP WORKING. THE BRIGHT LIGHTS COME ON, BUT THE DIM LIGHTS WILL NOT COME ON AT ALL. THE BULBS WERE CHECKED, AND THE DIMMER SWITCH. I'VE TAKEN IT TO 2 MECHANICS, AND NO ONE CAN FIND OUT WHAT'S WRONG WITH THE LIGHTS. I CAN'T GET MY TAGS RENEWED BECAUSE THE DIM LIGHTS DON'T WORK AT ALL. I'VE CALLED GMC TO SEE OF ANY RECALLS, AND THEY STATED ONLY REAR TAIL LIGHTS. I DEFINITELY THINK ITS A MANUFACTURERS DEFAULT, AND WOULD LIKE THE ISSUE RESOLVED. *TR

NHTSA ODI #10245732

61,000 miles · Apr 14, 2008
Exterior Lighting

WHILE ACCELERATING HEADLIGHTS WILL PERIODICALLY DIM AND BRIGHTEN WITHOUT WARNING. *TR

NHTSA ODI #10224523

Official recalls

1

05V198000 · Exterior Lighting:turn Signal

May 5, 2005

ON CERTAIN TRUCKS AND SPORT UTILITY VEHICLES, THE DRIVER WISHING TO SIGNAL A TURN BY MOVING THE DIRECTIONAL SIGNAL LEVER, (UP OR DOWN) MAY CAUSE THE FRONT MARKER/TURN LIGHTS AND REAR TURN LIGHTS TO FLASH IN A MANNER SIMILAR TO HAZARD WARNING, RATHER THAN FLASHING ON THE DESIRED SIDE ONLY.

Consequence & remedy

Consequence: THE DRIVER MAY NOT BE ABLE TO CLEARLY SIGNAL THEIR INTENTIONS TO TURN, CHANGE TRAVEL LANES, OR POTENTIALLY WARN OTHERS OF AN IMPAIRED VEHICLE OPERATING CONDITION INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SUSPECT FLASHER MODULES WITH A NEW FLASHER MODULE DESIGNED WITH SEALED RELAYS AND MORE DURABLE CONTACT MATERIAL INSIDE OF THE RELAYS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2005. ISUZU BEGAN MAILING OWNER LETTERS ON AUGUST 4, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, ISUZU AT 1-800-255-6727, BUICK AT 1-866-608-8080, AND OLDSMOBILE AT 1-800-630-6537.

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

4

RQ17002 · 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.