← New search

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.

About this comparison →

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, Other complaints

41 reports
Clear category filter
50,000 miles · Aug 9, 2011
Fuel System, Other

GAS GAUGE STOPPED WORKING AT 50K MILES. *TR

NHTSA ODI #10418231

57,000 miles · Aug 1, 2011
Fuel System, GasolineFuel System, Other

I BOUGHT A 2005 GMC ENVOY ROUGHLY 2 YEARS AGO WITH 67K AND AM EXPERIENCING ISSUES WITH THE FUEL SENSOR. WHEN I FILL UP WITH GAS THE SENSOR READS TANK AS EMPTY DIRECTLY AFTER AND SEEMS TO FLUCTUATE TO WHATEVER IT WANTS THE REST OF THE TIME. UPON RESEARCHING THE INTERNET WITH THIS ISSUE IT APPEARS THAT SEVERAL OTHER CONSUMERS ARE …

Read full complaint

I BOUGHT A 2005 GMC ENVOY ROUGHLY 2 YEARS AGO WITH 67K AND AM EXPERIENCING ISSUES WITH THE FUEL SENSOR. WHEN I FILL UP WITH GAS THE SENSOR READS TANK AS EMPTY DIRECTLY AFTER AND SEEMS TO FLUCTUATE TO WHATEVER IT WANTS THE REST OF THE TIME. UPON RESEARCHING THE INTERNET WITH THIS ISSUE IT APPEARS THAT SEVERAL OTHER CONSUMERS ARE HAVING THE SAME PROBLEMS AND GMC IS NOT WILLING TO HELP BECAUSE IT'S NOT A SAFETY RISK. I PERSONALLY DO SEE THIS AS A SAFETY RISK, IF YOU DON'T PAY PROPER ATTENTION YOU COULD RUN OUT OF GAS AND BE STRANDED ANYWHERE. WHEN I FOUND THE LINK TO THIS WEBSITE AND FORM AND THOUGHT IT WAS WORTH A SHOT TO HOPEFULLY GET THIS ISSUE RESOLVED FOR MYSELF AND THE MANY OTHERS THAT SPEND THEIR HARD EARNED MONEY ON THESE VEHICLES. *KB

NHTSA ODI #10416454

65,000 miles · Jul 21, 2011
Fuel System, GasolineFuel System, Other

2005 GMC ENVOY - GAS GAUGE MALFUNCTION - THE GAS GAUGE WILL REGISTER EMPTY EVEN THOUGH YOU JUST FILLED UP THE TANK. AFTER YOU DRIVE FOR SEVERAL MILES IT STARTS TO REGISTER SLOWLY, BUT DOES NOT REGISTER ACCURATELY. *KB

NHTSA ODI #10414011

48,000 miles · Jun 14, 2011
Fuel System, Other

2005 GMC ENVOY FUEL GAUGE SENSOR. VEHICLE HAS 48,000 MILES AND WHEN I FILL UP THE GAS TANK THE FUEL GAUGE GOES UP AND DOWN AND STAYS AT EMPTY WITH THE LIGHT FLASHING. I NEVER KNOW HOW MUCH FUEL IS IN THE VEHICLE. *TR

NHTSA ODI #10406820

127,197 miles · Jun 5, 2011
Fuel System, Other

I HAVE A 2005 ENVOY AND IT JUST STARTED SMELLING OF GAS FUMES REALLY BAD AND AS I WAS READING SOME INFORMATION ON YOUR SITE I HAVE ALSO AGREE IT IS A MANUFACTURING PROBLEM YOU SEE WHERE IT WAS SEALED NOT BY OIL CLAY OR ANY GOOEY SUBSTANCE OF THAT SOURCE ITS SECURED BY WELDING I KNOW THIS BECAUSE I WORK FOR NUMMI AND I WAS A QC I…

Read full complaint

I HAVE A 2005 ENVOY AND IT JUST STARTED SMELLING OF GAS FUMES REALLY BAD AND AS I WAS READING SOME INFORMATION ON YOUR SITE I HAVE ALSO AGREE IT IS A MANUFACTURING PROBLEM YOU SEE WHERE IT WAS SEALED NOT BY OIL CLAY OR ANY GOOEY SUBSTANCE OF THAT SOURCE ITS SECURED BY WELDING I KNOW THIS BECAUSE I WORK FOR NUMMI AND I WAS A QC INSPECTOR AND DID THE TEAR DOWN ON THE GAS TANKS FOR SAFETY IT SOUNDS LIKE SOME TANKS SLIP BY BECAUSE NOT EVERY ONE IS CK THERE RANDOM CHECKS I BELIEVE ITS THE O YES O RING THAT WAS NOT PROPERLY WELDED PROPERLY CAUSING LEAKS THAT IS THE GAS FUME I AM SMELLING IN MY CURRENT ENVOY (2005) .AND YES IT IS A SAFETY ISSUE PEOPLE CAN DIE FROM THESE FUMES YOU KNOW IT AND SO DUE I .LET ME TELL YOU ABOUT WHAT HAD HAPPEN ONE DAY THERE WAS THIS GENTLEMAN WHO WAS ON THE JOB AND LOTS OF GAS TANK SLIP THROUGH THAT DAY ROLLING OFF THE ASSEMBLY LINE AND SHIP OUT TO DEALER SHIPS WHERE THE O RINGS WERE NOT HOLDING UP DURING THE TEAR DOWN PROCESS OF THE INSPECTION. WELL NEED LESS TO SAY THE UNITS WENT OUT TO BE SOLD TO CONSUMER .AND THEY WANTED TO FIRE THE INSPECTOR BUT THEY JUST SUSPENDED HIM FOR A WEEK.ANOTHER PROBLEM OCCURRED ON MY INSPECTION ROUTE IN BODY N WELD I HAD FOUND A SPLIT ON THE FLOOR PAN OF THE COROLLA VERY LARGE AND HARD TO SEE GUESS I JUST GOT LUCKY BUT SO THE MANAGER AT THAT TIME WAS A FEMALE AND SHE WENT TO THE END OF THE ASSEMBLY LINE AND SURE ENOUGH THOSE SPLIT HAD BEEN SHIP OUT TO THE DEALER SHIPS THEY TURN A BLIND EYE TO THE ONES THAT WERE SHIP YOU SEE IF YOU KNOW NOTHING ABOUT MEDAL IT WILL CONTINUE TO SPLIT OF COURSE THE CARPET COVER IT WHO WILL KNOW .THE REMINDING ONES WELL THEY PLACE A SPOT WELD ON EACH SIDE OF THE SPLIT AND SOME SEALER. WITH THAT SAID I CERTAINLY BELIEVE THE MANUFACTURE IS CERTAINLY RESPONSIBLE AND PAY FOR THESE REPAIRS NO MATTER THE MILEAGE OR THE YEAR. BY THE WAY I WORK IN THE BODY-N-WELD SHOP. IT IS NOT A WARE AND TEAR ISSUE. *TR

NHTSA ODI #10404542

88,000 miles · May 10, 2011
Fuel System, Other

ON REGULAR BASIS WOULD ADD 10 GALLONS PER FILL UP, THEN DURING A LONG TRIP FILLED THE TANK COMPLETELY: WHICH THEN THE FUEL GAUGE SHOWED EMPTY. THEN WENT UP TO ABOUT HALF. NOW AFTER 10 GAL. FILL THE GAUGE READ EMPTY OR ABOUT 1/4. HAVE NOT NONE MUCH AFTER LEARNING THIS IS A VERY COMMON GM PROBLEM. FIRST TIME IN MY LIFE (DRIVING…

Read full complaint

ON REGULAR BASIS WOULD ADD 10 GALLONS PER FILL UP, THEN DURING A LONG TRIP FILLED THE TANK COMPLETELY: WHICH THEN THE FUEL GAUGE SHOWED EMPTY. THEN WENT UP TO ABOUT HALF. NOW AFTER 10 GAL. FILL THE GAUGE READ EMPTY OR ABOUT 1/4. HAVE NOT NONE MUCH AFTER LEARNING THIS IS A VERY COMMON GM PROBLEM. FIRST TIME IN MY LIFE (DRIVING 27 YEARS) RAN OUT OF GAS RIGHT IN THE MIDDLE OF A BUSY 4WAY INTERSECTION, HONEST TRUTH. DO NOT WANT TO HAVE MY FAMILY IN CAR AFTER THIS INCIDENT. *TR

NHTSA ODI #10399873

Mileage unknown · May 5, 2011
Fuel System, Other

OUR 2005 ENVOY HAD A GAS GAUGE MALFUNCTION AROUND 2 TO 3 YEARS AFTER WE BOUGHT IT AS BRAND NEW. GOOD THING IT WAS STILL COVERED BY OUR INSURANCE BUT AFTER A YEAR AND A HALF, THE SAME PROBLEM OCCURRED, AND IT WAS NOT COVERED BY THE INSURANCE ANYMORE SINCE IT'S ALREADY PASS 3 YEARS. HAVING IT FIXED IS QUITE COSTLY. I JUST RECE…

Read full complaint

OUR 2005 ENVOY HAD A GAS GAUGE MALFUNCTION AROUND 2 TO 3 YEARS AFTER WE BOUGHT IT AS BRAND NEW. GOOD THING IT WAS STILL COVERED BY OUR INSURANCE BUT AFTER A YEAR AND A HALF, THE SAME PROBLEM OCCURRED, AND IT WAS NOT COVERED BY THE INSURANCE ANYMORE SINCE IT'S ALREADY PASS 3 YEARS. HAVING IT FIXED IS QUITE COSTLY. I JUST RECENTLY FOUND OUT THAT THERE WERE 285 PEOPLE WHO COMPLAINED ON THE SAME PROBLEM. I DO HOPE THAT GMC WILL DO A RECALL ON 2005 GMC ENVOYS. *TR

NHTSA ODI #10399242

81,000 miles · May 4, 2011
Fuel System, Other

TL*THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE VEHICLE FUEL GAUGE WAS DEFECTIVE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR A LOCAL MECHANIC. THE MANUFACTURER WAS CONTACTED WHO DID NOT OFFER ANY ASSISTANCE SINCE THERE WERE NO RECALLS FOR THIS SPECIFIC FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURREN…

Read full complaint

TL*THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE VEHICLE FUEL GAUGE WAS DEFECTIVE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR A LOCAL MECHANIC. THE MANUFACTURER WAS CONTACTED WHO DID NOT OFFER ANY ASSISTANCE SINCE THERE WERE NO RECALLS FOR THIS SPECIFIC FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 81,000.

NHTSA ODI #10398916

50,000 miles · Apr 26, 2011
Fuel System, Other

FUEL GAUGE IN MY 2005 ENVOY QUIT WORKING AFTER A FULL TANK OF GAS WAS PUT IN. THE GAGE GOES UP AND DOWN AT ITS OWN WILL. WAS TOLD BY THE DEALERSHIP THAT IT WAS A FUEL SENSORY PROBLEM AND WOULD COST AROUND $600 TO FIX. THEY ALSO TOLD ME THAT THIS IS A COMMON PROBLEM WITH GMC VEHICLES. ON ONE SITE ALONE I FOUND 500+ COMPLAINTS ON …

Read full complaint

FUEL GAUGE IN MY 2005 ENVOY QUIT WORKING AFTER A FULL TANK OF GAS WAS PUT IN. THE GAGE GOES UP AND DOWN AT ITS OWN WILL. WAS TOLD BY THE DEALERSHIP THAT IT WAS A FUEL SENSORY PROBLEM AND WOULD COST AROUND $600 TO FIX. THEY ALSO TOLD ME THAT THIS IS A COMMON PROBLEM WITH GMC VEHICLES. ON ONE SITE ALONE I FOUND 500+ COMPLAINTS ON THIS ISSUE. I THINK ITS TIME FOR A RECALL. *TR

NHTSA ODI #10397458

Mileage unknown · Apr 23, 2011
Fuel System, Other

FUEL GAUGE ERRATIC AFTER WARRANTY EXPIRED. KNEW IT WOULD BE EXPENSIVE REPAIR. LIVED ON RESETTING TRIP ODOMETER EVERY 200 MILES AND WOULD FILL UP. THIS INCONVENIENCE LASTED TWO YEARS UNTIL CONSTANT AUDIO AND VISUAL LOW FUEL SIGNALS. ENDED UP PAYING $450 FOR REPAIR. COMPLETELY CONFIDENT THAT GM KNEW THE ORIGINAL WAS FAULTY. …

Read full complaint

FUEL GAUGE ERRATIC AFTER WARRANTY EXPIRED. KNEW IT WOULD BE EXPENSIVE REPAIR. LIVED ON RESETTING TRIP ODOMETER EVERY 200 MILES AND WOULD FILL UP. THIS INCONVENIENCE LASTED TWO YEARS UNTIL CONSTANT AUDIO AND VISUAL LOW FUEL SIGNALS. ENDED UP PAYING $450 FOR REPAIR. COMPLETELY CONFIDENT THAT GM KNEW THE ORIGINAL WAS FAULTY. *TR

NHTSA ODI #10397207

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.