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2005 GMC Envoy

Owner reports · Recalls · Investigations

More warning signs than most Envoy years

Owner complaints for the 2005 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

385 reports with mileage · 103 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 183 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 164 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 45 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

27 crash reports14 fire reports22 injury reports

Fuel System, Gasoline complaints

164 reports
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65,000 miles · May 2, 2011
Fuel System, Gasoline

AT 65,000 MILES THE FUEL GAUGE FAILED WITHOUT WARNING. GAUGE DROPPED TO EMPTY IMMEDIATELY AFTER A FILL AND HAS SINCE REMAINED THERE. NOTHING HAS BEEN DONE TO CORRECT THE PROBLEM AS I WAS TOLD BY THE LOCAL GMC DEALER IT WAS OUT OF WARRANTY, IT WAS NOT COVERED UNDER PAST FUEL GAUGE RECALLS, AND I REFUSE TO REWARD GMC FOR SUPPLYING…

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AT 65,000 MILES THE FUEL GAUGE FAILED WITHOUT WARNING. GAUGE DROPPED TO EMPTY IMMEDIATELY AFTER A FILL AND HAS SINCE REMAINED THERE. NOTHING HAS BEEN DONE TO CORRECT THE PROBLEM AS I WAS TOLD BY THE LOCAL GMC DEALER IT WAS OUT OF WARRANTY, IT WAS NOT COVERED UNDER PAST FUEL GAUGE RECALLS, AND I REFUSE TO REWARD GMC FOR SUPPLYING FAULTY PRODUCT BY PAYING THE QUOTED $800-$1000 TO REPLACE IT. THE SAFETY CONSEQUENCES OF RUNNING OUT OF FUEL ARE EXTENSIVE, FROM SLOWING AND BEING REAR ENDED TO BEING HIT ALONGSIDE THE ROAD WHILE GOING FOR GAS. *TR

NHTSA ODI #10398699

65,000 miles · May 2, 2011
Fuel System, Gasoline

INACCURATE FUEL GAUGE READING. CAR CAN RUN OUT OF GAS UNLESS CAREFULLY MONITORED BY OPERATOR. GAUGE BECAME FAULTY WITH TIME WHEN CAR WAS 3.5 YEARS OLD. AT FIRST WHEN TANK WAS FILLED, THE EMPTY LIGHT WOULD COME ON AND THEN SUDDENLY REGISTER AS FULL AFTER APPROXIMATELY 20 MILES OF OPERATION. GAUGE NOW ONLY REGISTERS 1/4TH TANK OR …

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INACCURATE FUEL GAUGE READING. CAR CAN RUN OUT OF GAS UNLESS CAREFULLY MONITORED BY OPERATOR. GAUGE BECAME FAULTY WITH TIME WHEN CAR WAS 3.5 YEARS OLD. AT FIRST WHEN TANK WAS FILLED, THE EMPTY LIGHT WOULD COME ON AND THEN SUDDENLY REGISTER AS FULL AFTER APPROXIMATELY 20 MILES OF OPERATION. GAUGE NOW ONLY REGISTERS 1/4TH TANK OR NOT AT ALL AFTER TANK IS FILLED. WITHOUT CAREFUL WATCH, THE CAR COULD RUN OUT OF GAS ON A HIGHWAY AND BE STRUCK OR CAUSE SIGNIFICANT PROBLEMS. DEALER ESTIMATED COST OF REPAIR = $650.00 AND STATED THAT IT WAS A COMMON PROBLEM FOR THIS MAKE AND MODEL. I DO NOT WISH TO PAY THIS EXORBITANT AMOUNT FOR REPAIR. IT APPEARS FROM MY RESEARCH THAT THIS IS A VERY DANGEROUS PROBLEM AND RAMPANT WITH THIS MAKE AND MODEL. *TR

NHTSA ODI #10398696

73,000 miles · May 2, 2011
Fuel System, Gasoline

PURCHASED NEW FROM DEALER 2005 GMC ENVOY - FUEL GAUGE READS EMPTY - SOMETIMES - IT WILL TELL YOU HAVE MORE GAS - MOST TIMES IT READS EMPTY. I RAN OUT OF FUEL ON SAT 4/30/11 - STUCK GOING UP A HILLED ENTRANCE INTO A MALL. THERE IS NO ACCURATE WAY TO TELL HOW MUCH FUEL LEFT IN TANK. PLEASE FORCE A RECALL FOR GMC INSTRUMENT PANE…

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PURCHASED NEW FROM DEALER 2005 GMC ENVOY - FUEL GAUGE READS EMPTY - SOMETIMES - IT WILL TELL YOU HAVE MORE GAS - MOST TIMES IT READS EMPTY. I RAN OUT OF FUEL ON SAT 4/30/11 - STUCK GOING UP A HILLED ENTRANCE INTO A MALL. THERE IS NO ACCURATE WAY TO TELL HOW MUCH FUEL LEFT IN TANK. PLEASE FORCE A RECALL FOR GMC INSTRUMENT PANEL PROBLEMS. ISSUE IS WIDESPREAD. *TR

NHTSA ODI #10398687

118,000 miles · May 2, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE FUEL GAUGE WOULD READ EMPTY WHEN THE FUEL TANK WAS FULL AND THE FUEL GAUGE WOULD READ FULL WHEN THE TANK WAS EMPTY. THE VEHICLE WAS NOT INSPECTED FOR THE FAILURE OR REPAIRED. THE FAILURE MILEAGE WAS 118,000 AND THE CURRENT MILEAGE WAS 120,000.

NHTSA ODI #10398652

92,000 miles · May 2, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT AFTER REFUELING THE VEHICLE, THE FUEL LEVEL GAUGE WOULD NOT RECORD AN ACCURATE FUEL LEVEL, DISPLAYING THAT THE FUEL TANK WAS EMPTY. THE DEALER WAS CONTACTED WHO ADVISED THAT THE REPAIRS FOR THE FUEL GAUGE SENSOR WOULD BE $500 AT THE CONTACTS EXPENSE. THE MANUFACTURER…

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TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT AFTER REFUELING THE VEHICLE, THE FUEL LEVEL GAUGE WOULD NOT RECORD AN ACCURATE FUEL LEVEL, DISPLAYING THAT THE FUEL TANK WAS EMPTY. THE DEALER WAS CONTACTED WHO ADVISED THAT THE REPAIRS FOR THE FUEL GAUGE SENSOR WOULD BE $500 AT THE CONTACTS EXPENSE. THE MANUFACTURER WAS CONTACTED WHO ADVISED THAT THERE WERE NO RECALLS FOR THE FAILURE AND OFFERED NO FURTHER ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 92,000 AND THE CURRENT MILEAGE WAS 101,000.

NHTSA ODI #10398632

80,000 miles · May 2, 2011
Fuel System, Gasoline

FUEL GAUGE DOES NOT WORK. *TR

NHTSA ODI #10398545

68,500 miles · May 2, 2011
Fuel System, Gasoline

I OWN A 2005 GMC ENVOY AND FOR THE LAST TWO MONTHS HAVE BEEN DEALING WITH A FAULTY FUEL GAUGE....I SAW ONLINE THAT A GOOD NUMBER OF OTHER GM OWNERS ARE HAVING THE SAME ISSUE. MY GAUGE JUST KEEPS READING EMPLTY TANK......EVEN WHEN TOTALLY FILLED, WILL RESET TO READ QUARTER OF TANK OF GAS WHEN IT'S STILL JUST ABOUT A FULL TAN…

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I OWN A 2005 GMC ENVOY AND FOR THE LAST TWO MONTHS HAVE BEEN DEALING WITH A FAULTY FUEL GAUGE....I SAW ONLINE THAT A GOOD NUMBER OF OTHER GM OWNERS ARE HAVING THE SAME ISSUE. MY GAUGE JUST KEEPS READING EMPLTY TANK......EVEN WHEN TOTALLY FILLED, WILL RESET TO READ QUARTER OF TANK OF GAS WHEN IT'S STILL JUST ABOUT A FULL TANK OF FUEL. EITHER BAD SENSOR OR BRAIN BOX......MADE IN CHINA!!! ANY HELP ..[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10398509

77,000 miles · May 1, 2011
Fuel System, Gasoline

THE FUEL GAUGE ON MY 2005 GMC ENVOY FAILED TO CORRECTLY REPORT THE QUANTITY OF GAS IN THE TANK STARTING AT ABOUT 30,000 MILES. IT ALWAYS REPORTS A VALUE THAT I KNOW IS WILDLY INACCURATE, AND EVEN SETS OFF THE LOW FUEL ALARM WHEN I KNOW THE TANK IS NEARLY FULL. I STOPPED RELYING ON THE GAS GAUGE A LONG TIME AGO, BECAUSE THAT WO…

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THE FUEL GAUGE ON MY 2005 GMC ENVOY FAILED TO CORRECTLY REPORT THE QUANTITY OF GAS IN THE TANK STARTING AT ABOUT 30,000 MILES. IT ALWAYS REPORTS A VALUE THAT I KNOW IS WILDLY INACCURATE, AND EVEN SETS OFF THE LOW FUEL ALARM WHEN I KNOW THE TANK IS NEARLY FULL. I STOPPED RELYING ON THE GAS GAUGE A LONG TIME AGO, BECAUSE THAT WOULD INEVITABLY LEAD TO THE VEHICLE RUNNING OUT OF FUEL CAUSING VEHICLE STALL WITH NO RESTART, WITH OBVIOUS SAFETY IMPLICATIONS. INSTEAD, I FUEL THE VEHICLE ON THE BASIS OF NUMBER OF MILES DRIVEN, AN INHERENTLY FLAWED METHOD WITH HIGHER PROBABILITY OF FAILURE. MY DEALER HAS ADVISED ME THAT REPAIR WOULD COST OVER $400.

NHTSA ODI #10398990

27,000 miles · Apr 30, 2011
Fuel System, Gasoline

FUEL LEVEL SENSOR, WHEN FILLING TANK, GUAGE GOES TO EMPTY, FUEL GAUGE IS UNRELIABLE, I'M AFRAID OF RUNNING OUT OF GAS ON THE FREEWAY IN TRAFFIC.

NHTSA ODI #10398987

48,000 miles · Apr 30, 2011
Fuel System, Gasoline

2005 GMC ENVOY FUEL GAUGE INACCURACIES. HED TO REPLACE THE FUEL SENSOR. AT DEALERSHIP. HAD LESS THAN 50,000 MILES ON VEHICLE WHEN THE PROBLEM OCCURRED. CONTACTED GMC CUSTOMER SUPPORT TO SEE IF THEY WOULD HELP WITH THECOSTS OF REPAIRING THE VEHICLE. AFTER 3 MONTHS OF WORKING WITH THEM THEY DENIED MY REQUEST. HAD TO PAY FOR THE D…

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2005 GMC ENVOY FUEL GAUGE INACCURACIES. HED TO REPLACE THE FUEL SENSOR. AT DEALERSHIP. HAD LESS THAN 50,000 MILES ON VEHICLE WHEN THE PROBLEM OCCURRED. CONTACTED GMC CUSTOMER SUPPORT TO SEE IF THEY WOULD HELP WITH THECOSTS OF REPAIRING THE VEHICLE. AFTER 3 MONTHS OF WORKING WITH THEM THEY DENIED MY REQUEST. HAD TO PAY FOR THE DIAGNOSTICS AND THEINSTALL OF THE PART WHICH CAME TO APPROX. $450.00. *TR

NHTSA ODI #10398370

Official recalls

2

06V417000 · Air Bags:frontal

Oct 31, 2006

CERTAIN VEHICLES ORIGINALLY BUILT WITH CLOTH SEATS THAT WERE EQUIPPED WITH AN AUTOMATIC AIR BAG PASSENGER SENSING SYSTEM AND LATER REUPHOLSTERED WITH AFTERMARKET LEATHER SEAT COVER KITS ARE INVOLVED. TESTING HAS INDICATED THAT THE AFTERMARKET LEATHER SEAT COVERS CAN CAUSE THE PASSENGER SENSING SYSTEM TO MALFUNCTION.

Consequence & remedy

Consequence: IF THE PASSENGER SENSING SYSTEM MALFUNCTIONS, THE FRONT AIR BAG ON THE PASSENGER SIDE MAY BE DISABLED WHEN IT SHOULD BE ENABLED, OR ENABLED WHEN IT SHOULD BE DISABLED. IN EITHER CASE, IN THE EVENT OF A CRASH THAT REQUIRES AIR BAG DEPLOYMENT, A FRONT PASSENGER'S LEVEL OF INJURY MAY BE INCREASED.

Remedy: BECAUSE A REPLACEMENT LEATHER SEAT COVER THAT IS COMPATIBLE WITH THE PASSENGER SENSING SYSTEM IS NOT AVAILABLE, GENERAL MOTORS (GM) WILL REPURCHASE THESE VEHICLES IN ACCORDANCE WITH THE TERMS STATED IN GM'S LETTER TO OWNERS. THE RECALL BEGAN ON NOVEMBER 6, 2006. OWNERS SHOULD CONTACT GM AT 1-877-477-1022 TO BEGIN THE PROCESS OF REPURCHASING THEIR VEHICLE.

05V035000 · Visibility:windshield

Feb 3, 2005

CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 212, 'WINDSHIELD MOUNTING.' THE WINDSHIELD URETHANE BEAD MAY NOT HAVE ADHERED TO THE BODY IN CERTAIN AREAS DURING THE CURE PROCESS.

Consequence & remedy

Consequence: IF A CRASH OCCURS, THE WINDSHIELD MAY NOT BE RETAINED, INCREASING THE RISK OF INJURY TO A VEHICLE OCCUPANT.

Remedy: DEALERS WILL REPLACE THE WINDSHIELD FREE OF CHARGE. THE RECALL BEGAN ON MARCH 10, 2005. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CHEVROLET AT 1-800-630-2438, 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

2

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.

DP10001 · Fuel Level Gauge System Failure

Opened Jan 7, 2010 · Closed May 23, 2011

Status: closed (inferred from source dates) · Fuel System, Other; Fuel System, Other:storage:fuel Gauge System

The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.

Additional source detail variants (2)

Fuel System, Other

The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.

Fuel System, Other:storage:fuel Gauge System

The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.