IllustrationTHE FUEL TANK NECK WHERE THE FUEL GOES INTO THE VEHICLE THEN DOWN TO THE GAS TANK IS CRACKED WHICH IS CAUSING A GAS LEAK & VAPORS. *TR
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.
About this comparison →How this year compares
Owner complaints by model year
Compare all Envoy 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
290–25K
4125–50K
7850–75K
4775–100K
52100–150K
41150K+
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 reports2004 GMC ENVOY, WELL MAINTAINED AT 158,000 MILES BEGAN TO EMIT AN ODOR OF GASOLINE. AT FIRST IT WAS ONLY SLIGHTLY NOTICEABLE, BUT OVERTIME IT'S BECOME VERY NOTICEABLE. INTERIOR AND EXTERIOR OF THE CAR SMELLS LIKE GASOLINE. NO GASOLINE IS LEAKED, ONLY FUMES ARE EMITTED. TOOK IT TO A LOCAL REPAIR SHOP AND THEY STATE THAT THERE…
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2004 GMC ENVOY, WELL MAINTAINED AT 158,000 MILES BEGAN TO EMIT AN ODOR OF GASOLINE. AT FIRST IT WAS ONLY SLIGHTLY NOTICEABLE, BUT OVERTIME IT'S BECOME VERY NOTICEABLE. INTERIOR AND EXTERIOR OF THE CAR SMELLS LIKE GASOLINE. NO GASOLINE IS LEAKED, ONLY FUMES ARE EMITTED. TOOK IT TO A LOCAL REPAIR SHOP AND THEY STATE THAT THERE IS A CRACK ON THE INLET OF THE FUEL TANK. REPAIR SHOP STATED MY MODEL IS NOT COVERED BY THE RECALL ISSUED FOR ENVOY XL OF THE SAME YEAR, BUT STATED IT IS EXACTLY THE SAME ISSUE AND THAT I SHOULD FILE A COMPLAINT HERE. ESTIMATE COST OF REPAIR $1000+. *TR
CHECK ENGINE LIGHT DIAGNOSED AS DTC CODE P0442 (EVAP LEAK). SMOKE TEST REVEALED CRACK IN FUEL TANK ASSEMBLY WHERE FILLER NECK HOSE MEETS THE FUEL TANK. *TR GMC ISSUED A BULLETIN NO.: 05-06-04-014A ON MARCH 21, 2005 REGARDING THE ABOVE REFERENCED DTC CODE AND ITS POSSIBLE CONNECTION TO A FRACTURE IN THE FUEL TANK, BUT HAS NO…
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CHECK ENGINE LIGHT DIAGNOSED AS DTC CODE P0442 (EVAP LEAK). SMOKE TEST REVEALED CRACK IN FUEL TANK ASSEMBLY WHERE FILLER NECK HOSE MEETS THE FUEL TANK. *TR GMC ISSUED A BULLETIN NO.: 05-06-04-014A ON MARCH 21, 2005 REGARDING THE ABOVE REFERENCED DTC CODE AND ITS POSSIBLE CONNECTION TO A FRACTURE IN THE FUEL TANK, BUT HAS NOT ISSUED A RECALL OR OTHER REMEDY FOR THIS DEFECT. VEHICLE IS UNSAFE DUE TO FUEL TANK FRACTURE. IN ADDITION, VEHICLE CANNOT BE REGISTERED BECAUSE IT CANNOT PASS SMOG TEST WITH CHECK ENGINE LIGHT ON. COST FOR REPAIR IS $1,300-$1,500.
A VERY STRONG ODOR OF GASOLINE IS INSIDE AND OUTSIDE OF MY CAR. WHEN THE CAR IS STARTED AND BEING DRIVEN THE SMELL IS MOST HEAVIEST. AFTER DRIVING AND IT SITS, YOU CAN CONTINUE TO SMELL THE GAS FUMES. I TOOK MY VEHICLE TO A CERTIFIED DEALERSHIP TO FIND OUT THE PROBLEM AND A DIAGNOSTIC WAS DONE. UNFORTUNATELY, I WAS TOLD THAT…
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A VERY STRONG ODOR OF GASOLINE IS INSIDE AND OUTSIDE OF MY CAR. WHEN THE CAR IS STARTED AND BEING DRIVEN THE SMELL IS MOST HEAVIEST. AFTER DRIVING AND IT SITS, YOU CAN CONTINUE TO SMELL THE GAS FUMES. I TOOK MY VEHICLE TO A CERTIFIED DEALERSHIP TO FIND OUT THE PROBLEM AND A DIAGNOSTIC WAS DONE. UNFORTUNATELY, I WAS TOLD THAT THE PROBLEM COULD NOT BE DETECTED. I CONTINUE TO BE AFRAID THAT MAYBE MY CAN IS GOING TO CATCH ON FIRE OR EXPLODE AT ANY TIME. AFTER DOING MY RESEARCH, I HAVE FOUND THAT THERE ARE MANY OWNERS OF GMC ENVOYS WITH THIS SAME PROBLEM. SOME OF THE MODELS HAVE BEEN RECALLED, BUT THIS ISSUE REACHES FAR BEYOND THOSE MODELS. ALL MAKE AND MODELS WITH THIS PROBLEM SHOULD BE RECALLED. *TR
THERE IS A STRONG GASOLINE SMELL INSIDE AND OUTSIDE THE VEHICLE. THE CHECK ENGINE LIGHT IS ON AND THE CODE IS INDICATING SOME TYPE OF VAPOR/EMISSIONS PROBLEM. I TOOK THE VEHICLE TO 2 DIFFERENT MECHANICS AND THEY BOTH FOUND THAT THE FUEL TANK FILLER AREA HAS A VAPOR AND LIQUID LEAK. THERE IS A TSB ISSUED BY GMC THAT COVERS THI…
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THERE IS A STRONG GASOLINE SMELL INSIDE AND OUTSIDE THE VEHICLE. THE CHECK ENGINE LIGHT IS ON AND THE CODE IS INDICATING SOME TYPE OF VAPOR/EMISSIONS PROBLEM. I TOOK THE VEHICLE TO 2 DIFFERENT MECHANICS AND THEY BOTH FOUND THAT THE FUEL TANK FILLER AREA HAS A VAPOR AND LIQUID LEAK. THERE IS A TSB ISSUED BY GMC THAT COVERS THIS SITUATION BUT THEY WILL ONLY HONOR IT ON VEHICLES PRIOR TO 2004. *TR
MY CAR IS LEAKING GAS AND I. CAN ONLY PUT 20 OR 30 DOLLARS WORTH IN AT A TIME WHERE MOST OF IT ENDS UP ON THE GROUND. THERE IS ALSO A VERY STRONG GAS SMELL. I'M TAKING IT IN TO BE FIXED BUT THIS IS OBVIOUSLY A PROBLEM SINCE I JUST READ THAT OTHER OWNERS ARE HAVING THIS PROBLEM SO THERE SHOULD BE A RECALL BEFORE SOMEONE IS SERIO…
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MY CAR IS LEAKING GAS AND I. CAN ONLY PUT 20 OR 30 DOLLARS WORTH IN AT A TIME WHERE MOST OF IT ENDS UP ON THE GROUND. THERE IS ALSO A VERY STRONG GAS SMELL. I'M TAKING IT IN TO BE FIXED BUT THIS IS OBVIOUSLY A PROBLEM SINCE I JUST READ THAT OTHER OWNERS ARE HAVING THIS PROBLEM SO THERE SHOULD BE A RECALL BEFORE SOMEONE IS SERIOUSLY HURT MY CHECK ENGINE LIGHT ALSO COMES ON FOR A WHILE AND THEN GOES OFF. THESE ARE PROBLEMS THAT REQUIRE A RECALL. *TR
TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT AFTER PARKING THE VEHICLE IN A RESIDENTIAL GARAGE, THERE WAS A STRONG GASOLINE FUEL ODOR COMING FROM THE INTERIOR AND EXTERIOR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO A MECHANIC, WHO INSPECTED THE VEHICLE AND FOUND THAT THERE WAS A FUEL TANK INLET CHECK VALVE FRACTU…
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TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT AFTER PARKING THE VEHICLE IN A RESIDENTIAL GARAGE, THERE WAS A STRONG GASOLINE FUEL ODOR COMING FROM THE INTERIOR AND EXTERIOR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO A MECHANIC, WHO INSPECTED THE VEHICLE AND FOUND THAT THERE WAS A FUEL TANK INLET CHECK VALVE FRACTURE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED AND STATED THERE WAS NO RECALL AND OFFERED NO FURTHER ASSISTANCE FOR THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 83,000.
TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT THERE WAS AN OVERPOWERING GASOLINE FUEL SMELL OUTSIDE OF THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC AND THE MECHANIC DISCOVERED A FUEL LEAK BETWEEN THE HOSE AND THE FUEL TANK. THE MECHANIC DID NOT REPLACE ANY COMPONENTS OF THE FUEL TANK OR THE HOSE…
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TL* THE CONTACT OWNS A 2004 GMC ENVOY. THE CONTACT STATED THAT THERE WAS AN OVERPOWERING GASOLINE FUEL SMELL OUTSIDE OF THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC AND THE MECHANIC DISCOVERED A FUEL LEAK BETWEEN THE HOSE AND THE FUEL TANK. THE MECHANIC DID NOT REPLACE ANY COMPONENTS OF THE FUEL TANK OR THE HOSES. THE FAILURE MILEAGE WAS 138,000.
Official recalls
105V198000 · 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
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.