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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 System, Gasoline complaints

24 reports
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71,055 miles · Dec 10, 2008
Fuel System, Gasoline

RECEIVED A SPECIAL CASE 07076 LETTER FROM GMC. TOOK 2004 GMC LETTER INDICATED IF YOU WERE NOT SEEING SYMPTOMS YOU ARE NOT TO TAKE IT TO DEALER. I ALREADY HAVE REGULAR MAINTENANCE SERVICE SCHEDULED AND BROUGHT THIS SC07076 LETTER TO DEALER TO INQUIRE ABOUT CASE. DEALER SERVICE ADVISOR RECOMMENDED TO HAVE THIS SC07076 SERVICE …

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RECEIVED A SPECIAL CASE 07076 LETTER FROM GMC. TOOK 2004 GMC LETTER INDICATED IF YOU WERE NOT SEEING SYMPTOMS YOU ARE NOT TO TAKE IT TO DEALER. I ALREADY HAVE REGULAR MAINTENANCE SERVICE SCHEDULED AND BROUGHT THIS SC07076 LETTER TO DEALER TO INQUIRE ABOUT CASE. DEALER SERVICE ADVISOR RECOMMENDED TO HAVE THIS SC07076 SERVICE PERFORMED AS PREVENTIVELY MAINTENANCE EVENTHOUGH THE VEHICLE WAS NOT EXHIBITING THESE SYMPTOMS. THE SERVICE WAS PERFORMED AND IMMEDIATELY THE VEHICLE BEGAN TO SHOW SYMPTOMS IN THE EXACT NATURE THAT WAS DESCRIBED IN THE SC07076 LETTER, FUEL FUMES, FUEL LEAK WHEN FILLING, SES LIGHT ON... TOOK VEHICLE BACK AND DEALER INDICATED THAT THEY WILL NOT PERFORM FREE SERVICE EVENTHOUGH IT SHOULD STILL BE COVERED UNDER STIPULATIONS OF SC07076 LETTER AS WELL AS THEIR WARRANTY POLICY. CURRENTLY THIS IS A HEALTH AND SAFETY ISSUES SINCE MY CHILDREN AND I GET HEADACHES FROM GAS FUMES WHEN NEEDING TO USE THE VEHICLE AS FEAR FOR OUR SAFETY SINCE FUEL LEAKS FROM GAS TANK NOW. I AM TRYING TO PREVENT ANY INJURY OR DEATH, MINE, A PASSENGER OR NEAR BY PERSON. APPARENTLY GMC AND DEALER ARE AWARE OF THE PROBLEMS BUT NOW IGNORE THE SITUATION DUE TO THEIR CURRENT FINANCIAL SITUATION. *TR

NHTSA ODI #10251287

75,000 miles · Jul 23, 2007
Fuel System, Gasoline

I OWN A 2004 GMC ENVOY WITH APPROXIMATELY 85,000 "HIGHWAY" MILES. MY CHECK ENGINE LIGHT CAME ON A FEW MONTHS AGO AN I HAD IT ANALYZED AT A LARGE AUTO REPAIR CHAIN. IT INDICATED A VACUUM LEAK. THE MECHANIC DETERMINED THAT THE TOP OF THE PVC GAS TANK WHERE THE INLET VALUE WAS MOUNTED TO THE TANK DURING MANUFACTURING WAS LIKELY …

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I OWN A 2004 GMC ENVOY WITH APPROXIMATELY 85,000 "HIGHWAY" MILES. MY CHECK ENGINE LIGHT CAME ON A FEW MONTHS AGO AN I HAD IT ANALYZED AT A LARGE AUTO REPAIR CHAIN. IT INDICATED A VACUUM LEAK. THE MECHANIC DETERMINED THAT THE TOP OF THE PVC GAS TANK WHERE THE INLET VALUE WAS MOUNTED TO THE TANK DURING MANUFACTURING WAS LIKELY THE SOURCE AS THERE WAS FUEL STAINS RUNNING DOWN THE TANK FROM THIS LOCATION! TO ADD SOME ADDITIONAL SUPPORT TO THIS MATTER, THE MECHANIC STATED THAT ANOTHER GENERAL MOTORS VEHICLE OF THE SAME TYPE HAD THE SAME, EXACT PROBLEM THE WEEK BEFORE. OBVIOUSLY THIS IS NOT MY PROBLEM ALONE. I CONTACTED GENERAL MOTORS AND LONG STORY SHORT, THEY REFUSED TO REPLACE THE TANK BECAUSE IT WAS OUT OF WARRANTY. THE GMC MECHANIC INDICATED THAT IF IT HAD 60,000 MILES OR FEWER, HE WOULD LIKELY HAVE REPLACED IT FOR ME. I ATTEMPTED TO EXPLAIN THAT A FUEL LEAK IS A VERY DANGEROUS PROBLEM AND I WAS CONCERNED ABOUT MY FAMILIES SAFETY. TO EXPLODE OR BURN IN AN ACCIDENT, BECAUSE OF THIS PROBLEM WAS UNACCEPTABLE. THIS IS NOT A MILEAGE FACTOR AND IT IS NOT A WEAR PART, IT WAS SIMPLY NOT PROPERLY SEALED WHEN IT WAS BEING MANUFACTURED. I FEEL THAT GENERAL MOTORS SHOULD CHECK INTO THIS MATTER AS IT IS A SERIOUS SAFETY ISSUE THAT LIKELY AFFECTS MANY ENVOYS AND TRAIL BLAZERS. I HOPE THAT THIS NOTICE WILL START A FULL INVESTIGATION AND A RECALL. A DEATH FROM THIS DEFECTIVE PART IS VERY POSSIBLE. THANK YOU, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10197211

47,400 miles · May 22, 2007
Fuel System, Gasoline

GASOLINE SMELLED/LEAK. REPLACED GAS TANK. *AK

NHTSA ODI #10191440

4,000 miles · Mar 20, 2006
Electrical SystemEngine And Engine CoolingEquipment

I BOUGHT MY GMC ENVOY IN JANUARY 2004 FOR APPROX. $42,000. THIS CAR HAS EVERYTHING. AFTER ABOUT 2 MONTHS OF THE PURCHASE, MY GPS WENT OUT AND HAD BEEN FIXED TWICE. MY BRAKES DO NOT ALWAYS WORK --SOMETIMES THEY SLIP ESPECIALLY WHEN I NEED THEM MOST -WHICH IS SCARY. GMC SAID THAT THEY HAVE HEARD ABOUT THIS PROBLEM BEFORE, BUT D…

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I BOUGHT MY GMC ENVOY IN JANUARY 2004 FOR APPROX. $42,000. THIS CAR HAS EVERYTHING. AFTER ABOUT 2 MONTHS OF THE PURCHASE, MY GPS WENT OUT AND HAD BEEN FIXED TWICE. MY BRAKES DO NOT ALWAYS WORK --SOMETIMES THEY SLIP ESPECIALLY WHEN I NEED THEM MOST -WHICH IS SCARY. GMC SAID THAT THEY HAVE HEARD ABOUT THIS PROBLEM BEFORE, BUT DID NOTHING TO RESOLVE THE PROBLEM. THE ENGINE STALLS PERIODICALLY. GMC SAID THEY DO NOT KNOW WHY. THE GAS GAUGE AND ODOMETER DO NOT WORK PROPERLY. WHEN I BROUGHT MY VEHICLE INTO NORTH COUNTY GMC DEALERSHIP IN SAN DIEGO FOR REPAIRS I MENTIONED MY GAS GAUGE DID NOT WORK ALONG WITH MANY OF THE OTHER ISSUES. AFTER THEY REPAIRED THE ODOMETER BY REPLACING THE CLUSTER, THE GAS GAUGE STILL DID NOT WORK. EVERY SINGLE TIME THESE PROBLEMS HAPPEN I AM FORCED TO PAY A $100 SERVICE CHARGE JUST SO THEY CAN LOOK AT IT AND BECAUSE I AM IN SALES, I AM ALSO FORCED TO GET A RENTAL CAR. AFTER ALL THIS, I AM STILL QUITE DISPLEASED WITH GMC. I HATE TO SAY IT BUT THEY ARE SUPPOSED TO BE THE BEST AMERICAN CAR ??PROFESSIONAL GRADE?? AND IF THIS IS TRUE I WILL NEVER BUY AN AMERICAN VEHICLE AGAIN. GMC SAID THEY WOULD BE CHECKING ON ALL THESE PROBLEMS AND EVERY SINGLE TIME I PICKED MY ENVOY UP AFTER THEY SUPPOSEDLY FIXED THE PROBLEMS, I FOUND SEVERAL ISSUES STILL UNRESOLVED. THEY SUGGEST I NEED TO SET ANOTHER MEETING TO BRING MY ENVOY IN AND OF COURSE WILL COST ANOTHER $100. *NM

NHTSA ODI #10153264

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.