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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

Fuel/propulsion System complaints

38 reports
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Mileage unknown · Aug 16, 2017
Fuel/propulsion System

GAS LEAK AT GAS TANK AND FILLER TUBE 14423 [XXX] TOOK VEHICLE TO DEALER FOR RECALL, THY SAID THY ORDERED PARTS, THAT`S MARCH/15/2016. NO RESULTS WITCH IS AUGUST/16/2017. ENGINE LIGHT ON ALWAYS SHOWING THE PROBLEM. PLUS YOU SMELL GAS AT TIMES IN THE ENVOY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (F…

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GAS LEAK AT GAS TANK AND FILLER TUBE 14423 [XXX] TOOK VEHICLE TO DEALER FOR RECALL, THY SAID THY ORDERED PARTS, THAT`S MARCH/15/2016. NO RESULTS WITCH IS AUGUST/16/2017. ENGINE LIGHT ON ALWAYS SHOWING THE PROBLEM. PLUS YOU SMELL GAS AT TIMES IN THE ENVOY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *JB *TR

NHTSA ODI #11015741

190,000 miles · Jun 12, 2017
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT THE FUEL TANK WAS LEAKING FUEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT AN UNKNOWN PART NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT DID NOT OFFER ANY ASSISTANCE. THE FAILURE MILE…

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TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT THE FUEL TANK WAS LEAKING FUEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT AN UNKNOWN PART NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT DID NOT OFFER ANY ASSISTANCE. THE FAILURE MILEAGE WAS 190,000.

NHTSA ODI #10994415

190,000 miles · Apr 6, 2017
Fuel/propulsion System

FUEL TANK CHECK VALVE MOUNT SEPARATES FROM TANK CAUSING A LEAK. GM WILL NOT FIX THIS DEFECT. THIS IS A SAFETY ISSUE THAT COULD RESULT IN FIRE OR EXPLOSION. I HAVE SEEN MANY OWNERS ON THE INTERNET WITH SAME ISSUE.

NHTSA ODI #10970934

107,300 miles · Jan 12, 2017
Fuel/propulsion System

P0455 SES LIGHT ALONG WITH FUEL TANK HARD TO FILL,FUEL BURPING BACK UP FILLER NECK WHEN CAP IS REMOVED FOR FILLING TANK,FUEL AROUND TO OF FILLER TUBE AT GAS CAP BEFORE REMOVAL FOR FILLING,FUEL SPELL WITH FUEL CAP ON,FIRST DAY THE P0455 SES LIGHT CAME ON REPLACE THE FUEL CAP WITH FACTORY AC DELCO REPLACEMENT CAP.

NHTSA ODI #10944948

109,000 miles · Dec 21, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY. WHILE THE VEHICLE WAS PARKED, AN ABNORMAL FUEL ODOR WAS PRESENT ON THE INSIDE AND OUTSIDE OF THE VEHICLE. THE CONTACT STATED THAT THERE WAS EVIDENCE OF A FUEL LEAK COMING FROM THE FUEL FILLER NECK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAI…

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TL* THE CONTACT OWNS A 2004 GMC ENVOY. WHILE THE VEHICLE WAS PARKED, AN ABNORMAL FUEL ODOR WAS PRESENT ON THE INSIDE AND OUTSIDE OF THE VEHICLE. THE CONTACT STATED THAT THERE WAS EVIDENCE OF A FUEL LEAK COMING FROM THE FUEL FILLER NECK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 109,000. THE VIN WAS NOT AVAILABLE. ..UPDATED 05/05/17 *BF *CN

NHTSA ODI #10936661

760,000 miles · Nov 14, 2016
Fuel/propulsion System

2004 XUV. 76000 GAS TANK HAS A LEAK , ABS MODULE IS OUT AND THERE IS NO RECALLS FOR ANY OF THIS ITMES. AIRBAG LIGHT IS ALWAYS ON SOLD NEW THAT WAY WERE. EVER ABLE TO REPAIR IT.

NHTSA ODI #10926017

Mileage unknown · Jun 20, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT NOTICED STRONG FUEL FUMES IN AND AROUND THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSTIC TESTING AND REPAIR. THE MANUFACTURER ADVISED THE CONTACT TO CALL THE DEALER. THE FAILURE MILEAGE WAS NOT AVAILABLE. UPDATED 08/04/16*LJ

NHTSA ODI #10875193

128,000 miles · Jun 1, 2016
EngineFuel/propulsion SystemStructureFire

VEHICLE WAS BEING DRIVING APPROXIMATELY AT 55 MPH. ENGINE LOSS POWER, GAS PEDAL LOST RESISTANCE AND WENT ALL THE WAY DOWN TO THE FLOOR BOARD. VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND ENGINE WAS STALLED AND ALL THE DASH LIGHTS WERE FLASHING ONE AND OFF. ENGINE STARTED TO HAVE WHITE SMOKE COMING FROM UNDER THE HOOD. …

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VEHICLE WAS BEING DRIVING APPROXIMATELY AT 55 MPH. ENGINE LOSS POWER, GAS PEDAL LOST RESISTANCE AND WENT ALL THE WAY DOWN TO THE FLOOR BOARD. VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND ENGINE WAS STALLED AND ALL THE DASH LIGHTS WERE FLASHING ONE AND OFF. ENGINE STARTED TO HAVE WHITE SMOKE COMING FROM UNDER THE HOOD. AFTER A FEW MINUTES, THE WHITE SMOKE TURNED INTO BLACK SMOKE AND THE ENGINE CAUGHT ON FIRE. VEHICLE WAS ENGULFED IN FLAMES AFTER A FEW MINUTES.

NHTSA ODI #10871973

Mileage unknown · May 13, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT RECEIVED NOTIFICATION OF A MANUFACTURERS RECALL ON THE FUEL SYSTEM HOWEVER, THE PARTS TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE CONTACT STATED THAT THE FUEL TANK WAS LEAKING. THE MANUFACT…

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TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT RECEIVED NOTIFICATION OF A MANUFACTURERS RECALL ON THE FUEL SYSTEM HOWEVER, THE PARTS TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE CONTACT STATED THAT THE FUEL TANK WAS LEAKING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. PARTS DISTRIBUTION DISCONNECT.

NHTSA ODI #10864791

65,000 miles · Apr 22, 2016
Fuel/propulsion System

EMISSION RELATED PROBLEM, OBD II CODE P0410 SECONDARY AIR INJECTION VALVE CHECK VALVE ASSOCIATED WITH AIR INJECTION SYSTEM PROBLEM, I HAD IT REPLACED TWICE ALREADY WITH ORIGINAL PART FROM DEALER VERY WELL KNOWN PROBLEM WITH EMISSION OVER THIS DEFECTIVE VALVE (WATER BUILD UP INSIDE/MALFUNCTION)

NHTSA ODI #10860910

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.